Balance shaft surface flaw detection method and device and intelligent terminal

Abstract

The invention relates to a balance shaft surface flaw detection method, a balance shaft surface flaw detection device and an intelligent terminal, and relates to an automobile part flaw detection technology. When the flaw detection device detects a preset crack signal, acquiring a sensor number for sending the signal; determining an electromagnet number in the corresponding detection hole based on the sent sensor number; controlling the electromagnets corresponding to the electromagnet numbers to be electrified so as to fix the balance shafts in the corresponding detection holes; a preset qualified tray is controlled to move to the position below the detection frame; and controlling all the clamping jaws to execute a preset loosening command so as to control qualified products to fall into a qualified tray. According to the invention, the cooperative control of automatic sorting of good products is realized, and the full-process automation of detection, treatment and classification is realized.

Description

Technical Field

[0001] The present invention relates to the field of automobile parts flaw detection technology, and in particular to a balance shaft surface flaw detection method, device and intelligent terminal. Background Art

[0002] Currently, the balance shaft is a mechanical device used in automobile engines to reduce engine vibration.

[0003] like Figure 1 The figure shows a balancing shaft. The current process flow of the balancing shaft is as follows: raw material incoming inspection - blanking - medium frequency heating - roll forging - die forging - hot trimming - controlled cooling - surface shot blasting - semi-finished product inspection - surface flaw detection - correction and warpage detection - laboratory analysis - packaging.

[0004] The current surface flaw detection technology for balance shafts refers to a large motor spindle crack flaw detection device based on ultrasonic waves with publication number CN117007679A: a bottom support assembly: including a base plate and a top plate and a movable ring arranged between the two, a mounting ring is rotatably connected inside the movable ring and is fixedly connected at equal angles to several ultrasonic flaw detection instruments; a shaft locking assembly: distributed at equal angles on the top plate to perform center positioning and fixation on each spindle; the shaft locking assembly is also provided with a driving member for rotationally adjusting the spindle. The shaft locking assembly and the bottom support assembly used in the present invention cooperate to perform flaw detection on multiple spindles at the same time.

[0005] Regarding the above-mentioned related technologies, after the spindles are confirmed after surface flaw detection, they are still in the movable ring with qualified spindles. Usually, manual observation is used to select qualified spindles and unqualified spindles for separation, which increases a lot of human resource consumption. Summary of the Invention

[0006] In order to more conveniently distinguish the main shaft after flaw detection, the present invention provides a balance shaft surface flaw detection method, system and intelligent terminal.

[0007] In a first aspect, the present invention provides a method for flaw detection on the surface of a balance shaft, which adopts the following technical solution: A method for flaw detection on the surface of a balance shaft, comprising: Control the flaw detection device to execute the preset flaw detection program; When the flaw detection device detects a preset crack signal, the sensor number that sends the signal is obtained; Determine the electromagnet number in the corresponding detection hole based on the issued sensor number; Control the electromagnet corresponding to the electromagnet number to energize to fix the balancing shaft in the corresponding detection hole; Control the preset qualified tray to move to the bottom of the inspection rack; Control all grippers to execute preset release commands to control qualified products to fall into qualified pallets.

[0008] By adopting the above technical solution, the crack signal is monitored in real time by executing the preset flaw detection program. When the preset crack signal is detected, the electromagnet of the corresponding detection hole is located according to the sensor number of the trigger signal, and the crack balance axis is locked by power. Then, the qualified pallet is moved to the area below the inspection frame, and all the grippers are synchronously controlled to release the qualified products to the pallet, realizing the coordinated control of the automatic sorting of good products and the automation of the entire process of inspection-disposal-classification.

[0009] Optionally, also include: After completing the flaw detection procedure, obtain the number corresponding to the electromagnet number; When the number of serial numbers is less than the preset detection threshold, the flaw detection procedure is repeated until the number of serial numbers exceeds the detection threshold; When the number of serial numbers is greater than the preset detection threshold, the qualified tray is controlled to move out from under the base plate, and the unqualified tray is controlled to move to under the detection rack; Control all electromagnets corresponding to the electromagnet numbers to cut off power so that unqualified products fall into the unqualified tray.

[0010] By adopting the above technical solution, the number of electromagnet triggering is counted after the flaw detection is completed. When the detection amount does not reach the preset threshold, the detection program is automatically executed in a loop to ensure the detection efficiency. When it reaches the threshold, the pallet is switched synchronously, the qualified pallet is removed, and the unqualified pallet is positioned in the detection area. Then, the power supply of all electromagnets is cut off so that the defective products fall accurately into the unqualified pallet, realizing the classification and processing of good and defective products.

[0011] Optionally, also include: Determine the number of the unqualified gripper based on the electromagnet number; Determine the qualified gripper number based on the unqualified gripper number and the preset gripper number; After the flaw detection program is completed, the electromagnet corresponding to the electromagnet number is controlled to continue to be energized; The gripper corresponding to the qualified gripper number is controlled to clamp the uninspected product on the preset uninspected tray and move it to the inspection rack for inspection.

[0012] By adopting the above technical solution, based on the dynamic identification of the gripper state: the unqualified gripper is reversely positioned by triggering the electromagnet, and the qualified gripper group is screened based on the preset number; after the inspection is completed, the electromagnetic locking state of the defective product is maintained, and at the same time, the qualified gripper is driven to accurately grab the uninspected product to the inspection station, forming an inspection process of "defect isolation-qualified product screening-cyclic inspection of products to be inspected", realizing a self-replenishing inspection process.

[0013] Optionally, another method for controlling the gripper to grip the uninspected product on a preset uninspected pallet after the flaw detection procedure is performed is also included, the method comprising: Determine the number of qualified products based on the qualified gripper numbers; Determine the number of defective products based on the defective jaw numbers; Calculate the total mass of qualified products based on the number of qualified products and the preset weight of each product; Calculate the total weight of non-conforming products based on the number of non-conforming products and the weight of each product; After the qualified products fall into the qualified pallet, obtain the net weight of the qualified pallet; When the net weight of the qualified pallet is equal to the total weight of the qualified products, the qualified pallet is controlled to move out from under the inspection rack; Control the preset unqualified tray to move to the bottom of the inspection rack, and control the electromagnet corresponding to the electromagnet number to cut off the power, so that the unqualified products fall into the unqualified tray; Obtain the net weight of the non-conforming pallet of non-conforming products; When the net weight of the unqualified pallet is equal to the total weight of the unqualified products, all grippers are controlled to grab the uninspected products and continue the flaw detection procedure.

[0014] By adopting the above technical solution, an intelligent sorting system with quality verification is established: the number of qualified / unqualified products is counted by the change in the number of gripper numbers, and the theoretical total weight is calculated based on the preset unit weight; when the measured net weight of a qualified pallet matches the theoretical value, it is automatically removed and switched to an unqualified pallet, triggering the electromagnet to power off to complete the sorting of defective products, and at the same time ensuring the completion of sorting through the weight verification of the unqualified pallet; finally, the gripper is controlled to re-grasp the product to be inspected to start a new round of inspection, thereby achieving accurate product sorting.

[0015] Optionally, the method of controlling the gripper corresponding to the qualified gripper number to grip the uninspected product on a preset uninspected pallet and move the uninspected product to the inspection rack for inspection includes: After controlling the gripper corresponding to the qualified gripper number to grip the uninspected product on a preset uninspected tray and move it to the inspection rack, an inspection hole image is acquired based on the determined qualified gripper number; When the inspection hole image is consistent with the preset idle inspection hole image, the flaw detection procedure is repeatedly executed until the inspection hole image is inconsistent with the preset idle inspection hole image; When the top view image of the detection hole is inconsistent with the image of the idle detection hole, the qualified gripper number corresponding to the detection hole image is defined as the abnormal gripper number; Analyze the top view image of the detection hole with the abnormal clamping jaw number to obtain the tilt angle and tilt horizontal length of the product corresponding to the abnormal clamping jaw number relative to the vertical direction; Based on the abnormal gripper number, the corresponding detection hole position coordinates are found from the preset position database; Determine the correction trajectory for the angle correction of the product corresponding to the abnormal gripper number based on the tilt angle, the tilt horizontal length and the detection hole position coordinates; Controlling the gripper to move along the correction trajectory and continuing to acquire the detection hole image, and defining the detection hole image as the correction image; When the corrected image and the image of the idle inspection hole are consistent, the flaw detection procedure is repeated; When the corrected image and the image of the idle detection hole are inconsistent, the tilt angle and the correction trajectory are re-determined until the corrected image and the image of the idle detection hole are consistent.

[0016] By adopting the above technical solution, after the product to be inspected is loaded, a top-view image of the inspection hole is collected for visual verification. When it does not match the idle state reference image, abnormal gripper identification is triggered; the product's tilt angle and offset are analyzed, and a correction trajectory is generated in combination with the inspection hole coordinate database; the gripper is adjusted through trajectory control, and real-time image comparison is used to achieve precise positioning; the product inspection posture is ensured, and the effective utilization rate of the inspection station is maintained through continuous image monitoring, realizing self-diagnosis and self-repair functions for abnormal working conditions.

[0017] Optionally, a triggering method for obtaining a top view image of the detection hole is further included, the method comprising: Control the untested product corresponding to the qualified gripper number to the corresponding detection hole position coordinate, move downward, and detect the current detection hole pressure; When the current detection hole pressure is equal to 0, continue to execute the flaw detection program until the current detection hole pressure is greater than 0; When the current detection hole pressure is greater than 0, obtain a top view image of the detection hole; By adopting the above technical solution, the qualified clamps accurately locate the uninspected products to the inspection hole coordinates and then perform the downward pressing action, and monitor the contact surface pressure value in real time for loading verification; when the pressure is zero, the test is continuously cycled until the pressure is greater than 0; after positive pressure is detected, the camera is immediately triggered to obtain a top view image of the inspection hole to ensure that no products are retained on the product inspection rack, providing working condition guarantee for subsequent inspection procedures.

[0018] Optionally, the method of controlling the gripper to move along the correction trajectory includes: Obtain an overall bird's-eye view image; Determining an upper and lower interleaving trajectory and an upper and lower overlapping order based on the corrected trajectory; When interleaved trajectories exist, the correction order is determined based on the order of top-to-bottom overlap; Control the grippers to move in the correct order along the correct trajectory; When the staggered trajectory does not exist, the gripper is controlled to move according to any correction trajectory until all the correction top view images are consistent with the idle detection hole images.

[0019] By adopting the above technical solution, by obtaining the overall overhead image of the detection area, analyzing and generating the composite correction trajectory of the upper and lower staggered features, the execution order is determined according to the overlapping order to implement step-by-step correction, and multi-track optimization is performed in parallel when there is no interference; by continuously obtaining the corrected detection hole image and comparing it with the reference image, multi-target collaborative correction under complex spatial structures is achieved, ensuring that the final position of all detection holes meets the re-inspection requirements.

[0020] Optionally, the method for determining the staggered trajectory and the order of the staggered overlap based on the corrected trajectory includes: Delineate the contour lines based on the overall overhead image; Identify product intersection coordinates based on contour lines; The abnormal horizontal distance is obtained based on the product intersection coordinates and the detection hole position coordinates; The overlap order is calculated based on the abnormal horizontal distance, the inclined horizontal length and the preset product length.

[0021] By adopting the above technical solution, the product contour line is extracted from the overall overhead image and the intersection coordinates are located, and the horizontal offset is calculated in combination with the detection hole position; the three-dimensional parameters of abnormal distance, inclination and product thickness are integrated, and the overlap priority is derived using spatial geometry algorithms to achieve autonomous planning of the correction sequence in complex stacking scenarios, providing precise trajectory support for multi-level product posture adjustment.

[0022] In a second aspect, the present invention provides a balance shaft surface flaw detection device, which should be as described above as follows: A balance shaft surface flaw detection device, comprising: Base plate to provide a flaw detection platform; a fixing rod connected to the base plate; A detection frame is fixedly connected to the fixed rod to provide a detection slot. The detection frame is provided with a plurality of detection holes for the balance shaft to pass through for detection. The inner side walls of the detection holes are provided with electromagnets. A rotating shaft connected to the fixed rod; A robotic arm is fixedly connected to the rotating shaft, the robotic arm is provided with a plurality of clamping claws for clamping the balance shaft, the clamping claws corresponding to the detection holes one by one, the robotic arm is provided with a camera facing the detection hole, and the inner wall of the detection hole is provided with a first pressure sensor for detecting the pressure in the detection hole; The qualified tray is rotatably connected to the base plate to receive qualified products dropped from the detection hole. The qualified tray is provided with a second pressure sensor for detecting the quality of qualified products. When the qualified tray receives the qualified products, the qualified tray is located below the detection rack. a reject tray rotatably connected to the base plate to receive reject products dropped from the inspection hole; the reject tray is provided with a third pressure sensor for detecting the quality of reject products; when the reject tray receives rejects, the reject tray is located below the inspection rack; and The uninspected tray is fixedly connected to one side of the base plate to place uninspected products.

[0023] By adopting the above technical solution, the crack signal is monitored in real time by executing the preset flaw detection program. When the preset crack signal is detected, the electromagnet of the corresponding detection hole is located according to the sensor number of the trigger signal, and the crack balance axis is locked by power. Then, the qualified pallet is moved to the area below the inspection frame, and all the grippers are synchronously controlled to release the qualified products to the pallet, realizing the coordinated control of the automatic sorting of good products and the automation of the entire process of inspection-disposal-classification.

[0024] In a third aspect, the present invention provides an intelligent terminal, which adopts the following technical solution: An intelligent terminal includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and execute any one of the methods described above.

[0025] By adopting the above technical solution, the crack signal is monitored in real time by executing the preset flaw detection program. When the preset crack signal is detected, the electromagnet of the corresponding detection hole is located according to the sensor number of the trigger signal, and the crack balance axis is locked by power. Then, the qualified pallet is moved to the area below the inspection frame, and all the grippers are synchronously controlled to release the qualified products to the pallet, realizing the coordinated control of the automatic sorting of good products and the automation of the entire process of inspection-disposal-classification.

[0026] In summary, the present invention includes at least one of the following beneficial technical effects: By executing the preset flaw detection program, the crack signal is monitored in real time. When the preset crack signal is detected, the electromagnet corresponding to the detection hole is located according to the sensor number of the trigger signal, and the crack balance axis is locked by power. Then, the qualified pallet is moved to the area below the inspection rack, and all grippers are synchronously controlled to release qualified products onto the pallet, realizing coordinated control of automatic sorting of qualified products and realizing the automation of the entire process of inspection, disposal and classification. By adopting the above technical solution, the overall top-view image of the inspection area is obtained, and a composite correction trajectory of the upper and lower interlaced features is analyzed and generated. The execution order is determined according to the overlapping order to implement step-by-step correction. When there is no interference, multi-track optimization is performed in parallel. By continuously acquiring the corrected inspection hole image and comparing it with the reference image, multi-target collaborative correction is achieved in complex spatial structures, ensuring that the final position of all inspection holes meets the re-inspection requirements. The product contour line is extracted from the overall overhead image and the intersection coordinates are located, and the horizontal offset is calculated based on the detection hole position. The three-dimensional parameters of abnormal distance, inclination and product thickness are integrated, and the overlap priority is derived using spatial geometry algorithms to achieve autonomous planning of the correction sequence in complex stacking scenarios, providing precise trajectory support for multi-level product posture adjustment. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of a balance shaft in the related art.

[0028] Figure 2 This is a flow chart of a balance shaft surface flaw detection method in an embodiment of the present application.

[0029] Figure 3 It is a structural schematic diagram of the flaw detection device in an embodiment of the present application.

[0030] Figure 4 This is a flow chart of the steps further included in a method for flaw detection on the surface of a balance shaft in an embodiment of the present application.

[0031] Figure 5 This is a flow chart of further steps included in a method for flaw detection on the surface of a balance shaft in an embodiment of the present application.

[0032] Figure 6 This is a flow chart of another method for controlling the clamping jaws to clamp uninspected products on a preset uninspected pallet after executing the flaw detection program in an embodiment of the present application.

[0033] Figure 7 This is a flow chart of a method in an embodiment of the present application for controlling a gripper corresponding to a qualified gripper number to grip an uninspected product on a preset uninspected pallet and move the product to an inspection rack for inspection.

[0034] Figure 8 It is a flowchart of a triggering method for obtaining a top view image of a detection hole in an embodiment of the present application.

[0035] Figure 9 This is a flow chart of a method for controlling the movement of the clamping jaws according to a correction trajectory in an embodiment of the present application.

[0036] Figure 10This is a flowchart of a method for determining an upper and lower interleaving trajectory and an upper and lower overlapping order based on a correction trajectory in an embodiment of the present application.

[0037] The names of the parts indicated by the numerical labels in the above drawings are as follows: 1. Base plate; 2. Fixed rod; 3. Inspection frame; 31. Inspection hole; 4. Rotating axis; 5. Robotic arm; 51. Gripper; 6. Qualified pallet; 7. Unqualified pallet; 8. Uninspected pallet. DETAILED DESCRIPTION

[0038] The present invention is further described in detail below with reference to the accompanying drawings and embodiments.

[0039] The embodiment of the present invention discloses a method for flaw detection on the surface of a balance shaft. Figure 2 , a balance shaft surface flaw detection method, comprising: Step 100: Control the flaw detection device to execute a preset flaw detection program.

[0040] The flaw detection device is used to Figure 1 The device for flaw detection of the balance shaft shown in the figure. Figure 3 The flaw detection device includes a base plate 1, a fixed rod 2, a detection frame 3, a rotating shaft 4, a robotic arm 5, a qualified pallet 6, an unqualified pallet 7 and an uninspected pallet 8. The detection frame 3 serves as a flaw detection platform. The fixed rod 2 is fixedly connected to the base plate 1. The detection frame 3 is fixedly connected to the fixed rod 2 to provide a detection slot. The detection frame 3 is provided with a detection hole 31 for the balance shaft to pass through for detection. There are several detection holes 31, and an electromagnet (not shown) is installed on the inner side wall of the detection hole 31. When the electromagnet is energized, the balance shaft in the detection hole 31 can be magnetically fixed. The rotating shaft 4 is rotatably connected to the fixed rod 2. The robotic arm 5 is fixedly connected to the rotating shaft 4 so as to rotate as the rotating shaft 4 rotates. The robotic arm 5 is equipped with several clamps 51 corresponding to the detection holes 31. Here, a suction cup can also be provided on the clamp 51 to clamp the smooth round shaft product to prevent it from falling. A camera (not shown) is mounted on the robotic arm 5, facing the detection hole 31. A first pressure sensor (not shown) for detecting the pressure inside the detection hole 31 is mounted on the inner wall of the detection hole 31. The qualified tray 6 is rotatably connected to the base plate 1 to receive the qualified products that fall. A second pressure sensor (not shown) for detecting the quality of qualified products is mounted inside the qualified tray 6. The unqualified tray 7 is rotatably connected to the base plate 1 to receive the unqualified products. A third pressure sensor (not shown) is mounted inside the tray to detect the quality of unqualified products. The untested tray 8 is fixedly connected to one side of the base plate 1 for placing untested products. In the embodiment of the present application, the untested products are placed according to the arrangement of the clamping jaws 51 to facilitate the clamping of the clamping jaws 51.

[0041] The flaw detection procedure is used to inspect the balance shaft. This process is performed using a mechanical flaw detector (not shown). This flaw detector can be a Type A pulse reflection ultrasonic flaw detector, which records abnormal signals in real time when the reflected amplitude exceeds the standard component amplitude and simultaneously marks the position coordinates.

[0042] Step 101: When a flaw detection device detects a preset crack signal, the sensor number of the crack signal is obtained.

[0043] A crack signal is a signal emitted by a flaw detector when the reflected amplitude exceeds the amplitude of the reference component. The test is essentially focused on the reflected amplitude. When the reflected amplitude exceeds the amplitude of the reference component, it is considered a crack signal and output.

[0044] The sensor number is the sensor's ID, which is manually assigned based on the sensor's installation. When a sensor with that ID detects a crack signal, it automatically sends the signal along with its ID to the system, where it is received and extracted, generating the sensor number.

[0045] By combining multiple sensors with surface positioning, positioning accuracy is improved, cracks are automatically identified and associated with sensor numbers, reducing manual intervention.

[0046] Step 102: Determine the electromagnet number in the corresponding detection hole 31 based on the issued sensor number.

[0047] The solenoid number is the number of the electromagnet. After installation, each electromagnet is manually numbered in a specific sequence. This number is then sent to the system, generating the solenoid number. This is determined by associating the sensor number with the corresponding solenoid number. When either number is found, the other number is automatically associated and displayed.

[0048] Step 103 : Controlling the electromagnet corresponding to the electromagnet number to be energized to fix the balancing shaft in the corresponding detection hole 31 .

[0049] When the sensor number corresponding to one of the electromagnets is extracted by the system, the corresponding electromagnet is automatically energized and generates magnetic induction with the balance shaft, thereby fixing the balance shaft in the detection hole 31, so that unqualified products are automatically marked and the position information of the detection frame 3 is retained, which is convenient for subsequent quality traceability.

[0050] In order to prevent interference to the surrounding balance shaft and electromagnet, a shielding cover is provided around the electromagnet, and the range of electromagnetic induction is only within the detection hole 31 .

[0051] Step 104 : Control the preset qualified tray 6 to move to the bottom of the detection rack 3 .

[0052] The qualified tray 6 is driven by a motor to rotate the corresponding rod, so that the qualified tray 6 rotates to the bottom of the detection rack 3.

[0053] Step 105 : Control all the clamps 51 to execute a preset release command to control the qualified products to fall into the qualified tray 6 .

[0054] The release command is a command for the clamping jaws 51 to release the balancing shaft after the flaw detection procedure is completed. Before this, the qualified tray 6 moves to the bottom of the detection frame 3.

[0055] In addition, if the weight of the balancing shaft is large, other operations can be used to assist in clamping the balancing shaft. For example, a small cylinder is set inside, and a clamping block is set on the piston rod. The cylinder in the detection hole 31 of the unqualified product is expanded, so that the piston rod supports the balancing shaft in the detection hole 31. At this time, when step 105 is executed, the cylinder in the qualified product will be retracted, causing the balancing shaft to lose support and fall.

[0056] Reference Figure 4 , also includes: Step 200: After executing the flaw detection program, obtain the number of numbers corresponding to the electromagnet numbers.

[0057] The number of numbers is the number of electromagnets that are energized. When the electromagnets are energized, the system counts the numbers of the electromagnets extracted to obtain the number of numbers.

[0058] This step may be performed after any one of steps 103-105.

[0059] Step 201: When the number of serial numbers is less than a preset detection threshold, the flaw detection process is repeatedly executed until the number of serial numbers exceeds the detection threshold.

[0060] The critical value of the detection amount is the maximum number of electromagnets that are simultaneously energized in the system. If this value is exceeded, it means that the load on the detection rack 3 is too large, and the number of products to be detected is small, which affects the detection efficiency. This value is set by humans, and then the number of products to be detected is fixed, and then the detection is carried out in the manner of steps 100-203. After all the products to be detected are detected, it is observed at which value the efficiency is significantly different when the value exceeds and does not exceed. When the number of numbers is less than the critical value of the detection amount, it means that the critical value has not been reached at this time. It is more efficient to continue the detection without recycling unqualified products. Therefore, the electromagnet corresponding to the electromagnet number is continuously energized, and then the flaw detection procedure is repeated until the number of numbers exceeds the critical value of the detection amount.

[0061] Based on threshold judgment, crack products can be efficiently sorted to improve detection efficiency; the number of sensor numbers can be counted and accurately judged to reduce the false detection rate.

[0062] Step 202 : When the number of serial numbers is greater than a preset detection threshold, the qualified tray 6 is controlled to move out from under the base plate 1 , and the unqualified tray 7 is controlled to move to under the detection rack 3 .

[0063] When it is greater than the critical value of the detection volume, it means that the unqualified products will be put down at this time, and then all the products to be tested will be tested at the same time. If it is more efficient, the tray below will be removed and replaced to take over the unqualified products.

[0064] Step 203 : Controlling all electromagnets corresponding to the electromagnet numbers to be powered off, so that unqualified products fall into the unqualified tray 7 .

[0065] The unqualified tray 7 is driven by a motor and rotates to the bottom of the detection rack 3.

[0066] Reference Figure 5 , also includes: Step 300: Determine the qualified gripper number based on the unqualified gripper number and the preset gripper number.

[0067] The number of the unqualified gripper is because the previous gripping process was holding an unqualified product, and this product has not yet fallen from the inspection rack 3 onto the unqualified tray 7 below. Therefore, the number of the gripper 51 that is no longer needed to grip the untested product is not needed. The gripper number is the number of all grippers 51. It is determined by personnel in this field after installing and numbering all grippers 51. The number of the qualified gripper is the number of the gripper that needs to be moved to the untested tray 8 to grip the untested product.

[0068] The determination method is to match the unqualified gripper number with the gripper number. If the gripper number does not successfully match the unqualified gripper number, the corresponding gripper number is the qualified gripper number.

[0069] Step 301: After the flaw detection program is executed, the electromagnet corresponding to the electromagnet number is controlled to continue to be energized.

[0070] Here, the electromagnet corresponding to the electromagnet number continues to be energized, so that all the previously unqualified products remain on the detection rack 3.

[0071] Step 302: Control the gripper 51 corresponding to the qualified gripper number to grip the uninspected product on the uninspected tray 8 and move it to the inspection rack 3 for inspection.

[0072] Reference Figure 6 , further comprising another method of controlling the clamping jaws 51 to clamp the uninspected product on the preset uninspected tray 8 after executing the flaw detection procedure, the method comprising: Step 400: Determine the number of qualified products based on the qualified gripper numbers.

[0073] The number of qualified products is the number of qualified products that fall into the qualified tray 6 after the clamping jaws 51 are released. The determination method is that because the qualified clamping jaw number and the qualified product number are the same, the number of the two is the same, so only the number of qualified clamping jaw numbers in this time needs to be calculated.

[0074] Step 401: Determine the number of unqualified products based on the unqualified gripper numbers.

[0075] The number of unqualified products is the number of unqualified products that fall from the inspection rack 3 into the unqualified tray 7. The method of determining is that since the unqualified gripper number and the unqualified product number are the same, the number of the two is the same, so only the number of unqualified gripper numbers in this time needs to be calculated.

[0076] Step 402: Calculate the total mass of qualified products based on the number of qualified products and the preset weight of a single product.

[0077] The total mass of qualified products is the mass of qualified products that fall into the qualified tray 6. It is calculated by multiplying the number of qualified products by the weight of each product.

[0078] Step 403: Calculate the total weight of the unqualified products based on the number of unqualified products and the weight of each product.

[0079] The total mass of the unqualified products is the mass of the unqualified products falling into the unqualified tray 7 .

[0080] Step 404: After the qualified products fall into the qualified tray 6, the net weight of the qualified tray is obtained.

[0081] The net weight of the qualified tray is the weight of the qualified products dropped from the qualified tray 6. The weight change is calculated here. That is, there is a weight value before the drop and a weight value after the drop. The net weight of the qualified tray is obtained by subtracting the two weight values. This value is obtained by the second pressure sensor and recorded in the system.

[0082] Step 405 : When the net weight of the qualified tray is equal to the total weight of the qualified products, the qualified tray 6 is controlled to move out from under the inspection rack 3 .

[0083] The condition for judging here is to determine whether the qualified products have completely fallen into the qualified tray 6. If the net weight of the qualified tray is less than the total mass of the qualified products, it means that the qualified products have not been completely dropped at this time, and then continue to wait until the net weight of the qualified tray is equal to the total mass of the qualified products.

[0084] Step 406 : Control the preset unqualified tray 7 to move to the bottom of the inspection rack 3 , and control the electromagnet corresponding to the electromagnet number to be powered off, so as to control the unqualified products to fall into the unqualified tray 7 .

[0085] The purpose of this step after step 405 is that after the qualified products have been dropped, the next products to be dropped are unqualified products.

[0086] Step 407: Obtain the net weight of the unqualified pallet of unqualified products.

[0087] The net weight of the failed tray is the weight of the failed products dropped from the failed tray 7. The weight change is calculated here: the weight before the drop is calculated, and the weight after the drop is calculated. The net weight of the failed tray is obtained by subtracting the two weight values. This weight is obtained by the third pressure sensor and recorded in the system.

[0088] Step 408: When the net weight of the unqualified pallet is equal to the total weight of the unqualified products, control all the grippers 51 to grip the untested products and continue to perform the flaw detection procedure.

[0089] When the net weight of the unqualified pallet is equal to the total weight of the unqualified products, it means that the qualified products and unqualified products of the same batch on the inspection rack 3 have been inspected and distinguished, and there is no balance shaft remaining in any inspection hole 31 on the inspection rack 3. Therefore, all the clamping jaws 51 can perform the next clamping operation, and then all the inspection holes 31 can continue to perform the flaw detection procedure.

[0090] Reference Figure 7 The method of controlling the gripper 51 corresponding to the qualified gripper number to grip the uninspected product on the preset uninspected tray 8 and move it to the inspection rack 3 for inspection includes: Step 500 : After controlling the gripper 51 corresponding to the qualified gripper number to grip the uninspected product on the preset uninspected tray 8 and move it to the inspection rack 3 , an inspection hole image is acquired based on the determined qualified gripper number.

[0091] The detection hole image is an image of the detection hole 31 corresponding to the real-time qualified gripper number, and is acquired by a camera on the robot arm 5 facing the detection hole 31 of the qualified gripper number.

[0092] High-precision robotic arms and vision systems are used to ensure the accuracy of clamping position and image acquisition, reducing repeated inspections due to human error. Automatic acquisition and analysis of inspection hole images support real-time data recording and traceability, facilitating the generation of quality reports.

[0093] Step 501 : When the inspection hole image is consistent with the preset idle inspection hole image, the flaw detection procedure is repeatedly executed until the inspection hole image is no longer consistent with the preset idle inspection hole image.

[0094] The idle inspection hole image is an image of the inspection hole 31 when no product is in the inspection hole 31. The image is taken before the flaw detection process starts.

[0095] When the detection hole image is consistent with the idle detection hole image, it means that there is no balancing shaft in the detection hole 31 at this time, and the flaw detection procedure can be continued.

[0096] Step 502: When the detection hole image and the idle detection hole image are inconsistent, the qualified gripper number corresponding to the detection hole image is defined as an abnormal gripper number.

[0097] The abnormal gripper number is the number of the qualified gripper 51 corresponding to the inspection hole 31 where the qualified product is stuck. When the inspection hole image corresponding to one of the grippers 51 corresponding to the qualified gripper number does not match the image of the idle inspection hole, the image with its own number is automatically sent to the system to obtain the abnormal gripper number.

[0098] Step 503: Analyze the detection hole image of the abnormal gripper number to obtain the tilt angle and tilt horizontal length of the product corresponding to the abnormal gripper number.

[0099] The tilt angle is the angle between the balance shaft, which is stuck in the detection hole 31, on the detection frame 3 and the horizontal direction. Here, the detection hole 31 is used as the center point, and a certain direction is used as 0°. The balance shaft profile is then determined by analyzing the color characteristics of the balance shaft. Based on the balance shaft profile, the central axis is determined. The angle between the central axis and the set 0° direction is the tilt angle.

[0100] The tilted horizontal length is the projected length of the balance shaft stuck in the detection hole 31 on the image. The distance between the intersection of the corresponding central axis and the balance shaft contour and the center point of the detection hole 31 is the tilted horizontal length.

[0101] Step 504: Based on the abnormal gripper number, the corresponding detection hole position coordinates are searched from a preset position database.

[0102] The detection hole position coordinates are the position of the detection hole 31 on the detection frame 3, which can also be the position in the entire space, with the detection frame 3 as the reference system. The position of the center of the detection hole 31 on the detection plate is manually recorded in the system. The mapping relationship between the abnormal clamping jaw number and the detection hole position coordinates is stored in the database. The staff will match each clamping jaw 51 with the detection hole 31, and after moving it, observe which hole the balance shaft clamped by the clamping jaw 51 falls into, and then record it. When the system receives the abnormal clamping jaw number, it automatically finds the corresponding detection hole position coordinates and outputs them.

[0103] Step 505: Determine a correction trajectory for angle correction of the product corresponding to the abnormal gripper number based on the tilt angle, the tilt horizontal length, and the detection hole position coordinates.

[0104] The correction trajectory is the movement path required by the gripper 51 to adjust the product's position so that the corresponding balancing shaft, clamped in the detection hole 31, falls onto the pallet. This is determined by drawing a line along the centerline of the balancing shaft using the horizontal length and tilt angle. The correction trajectory starts at one of the endpoints of this line segment that is not at the detection hole 31, and ends at the detection hole coordinates. The line segment connecting these two points is the correction trajectory.

[0105] Step 506: Control the clamping jaw 51 to move along the correction trajectory and continue to acquire the detection hole image, and define the detection hole image as the correction image.

[0106] The correction image is the image of the detection hole after the clamping jaws 51 move the balancing shaft along the correction trajectory. The purpose of controlling the movement of the clamping jaws 51 along the correction trajectory is to make the balancing shaft clamped by the clamping jaws 51 hit the balancing shaft stuck in the detection hole 31 and push the balancing shaft to be straightened.

[0107] Step 507: Continue to repeatedly execute the flaw detection procedure when the corrected image is consistent with the image of the idle detection hole.

[0108] When the corrected image is consistent with the image of the idle inspection hole, it means that the stuck balance shaft has fallen, and the flaw detection procedure can be continued.

[0109] Step 508 : When the corrected image and the image of the free detection hole are inconsistent, the tilt angle and the correction trajectory are re-determined until the corrected image and the image of the free detection hole are consistent.

[0110] When the correction image and the idle detection hole image are inconsistent, it means that there is no correction, or the corresponding balance axis is separated from the contact with the correction balance axis and moves to both sides during the movement, so the tilt angle and correction trajectory need to be re-determined, so steps 502-506 need to be re-executed.

[0111] Reference Figure 8 , further comprising a triggering method for acquiring an image of the detection hole, the method comprising: Step 600: Control the uninspected product corresponding to the qualified gripper number to the corresponding detection hole position coordinate, move downward, and detect the current detection hole pressure.

[0112] The pressure of the detection hole 31 is the resistance of the detection hole 31 that is felt by the clamping jaw 51 and is detected by a pressure sensor.

[0113] Step 601: When the current detection hole pressure is equal to 0, continue to execute the flaw detection procedure until the current detection hole pressure is greater than 0.

[0114] When the current detection hole pressure is equal to 0, it indicates that there is no impurity in the detection hole 31 or the balance shaft on the balance shaft interference clamp 51 enters the detection hole 31 for detection, and there is no need to start acquiring the detection hole image.

[0115] Step 602: When the current detection hole pressure is greater than 0, obtain the detection hole image.

[0116] When the current detection hole pressure is greater than 0, it indicates that there is something blocking the detection hole 31 , and thus the step of acquiring the detection hole image is triggered.

[0117] Reference Figure 9 , the method of controlling the clamping jaw 51 to move along the correction trajectory includes: Step 700: Acquire an overall top-view image.

[0118] The overall top view image is the overall image of all the detection holes 31. Here, the detection hole image and the detection hole image can be acquired by the same camera. The overall top view image is the entire image, while the detection hole image is a portion of the overall top view image, that is, the image of the corresponding detection hole 31 area.

[0119] Step 701: Determine an up-and-down interleaving trajectory and an up-and-down overlapping order based on the corrected trajectory.

[0120] The intersecting trajectory is the trajectory where the corresponding trajectory lines of two corrected trajectories intersect. The judgment method here is to select any two corrected trajectories and then determine whether there is an overlap point.

[0121] The top-to-bottom overlap order is the order from top to bottom within the interlaced correction trajectory. Here, you can analyze which contour line on the image is complete (the top one) and which is the bottom one, and then determine the order accordingly. You can also use subsequent steps to determine the order.

[0122] Step 702: Determine a correction order based on the top-bottom overlapping order when interleaved tracks exist.

[0123] The correction order is the order in which the corresponding clamping jaws 51 are aligned for the intersecting balancing axes. This is determined by ensuring that the correction track is consistent with the overlapping order. That is, when the correction track is at the top in the overlapping order, it is also the first in the correction order.

[0124] Dynamic priority allocation is used to reduce the path conflicts of the gripper 51 and improve the system's self-adjustment response speed in complex environments.

[0125] Step 703: Control the clamping jaw 51 to move along the correction trajectory in the correction sequence.

[0126] Step 704 : When the interleaved trajectory does not exist, the gripper 51 is controlled to move along any one of the correction trajectories until all the correction top view images are consistent with the idle detection hole images.

[0127] If there is no staggered track, it means that there is no need to sort and you can start moving directly.

[0128] Reference Figure 10 The method for determining the staggered trajectory and the order of the staggered overlap based on the corrected trajectory includes: Step 800: Divide the contour lines based on the overall overhead image.

[0129] The contour line is the contour line corresponding to the balance shaft feature. The division method is to directly determine it according to the boundary line of the corresponding image color, that is, the detection frame 3 is painted in a different color from the balance shaft, and then the two can be distinguished by color.

[0130] Step 801: Identify product intersection coordinates based on contour lines.

[0131] The product intersection coordinates are the coordinates of the horizontal intersection of the two balancing axes. These coordinates are identified by comparing each point within the contour line with each point on the other balancing axis's contour line. If the coordinates of the points match, they are the product intersection coordinates. This identification method can also be simplified to the method used in step 701 to determine the corrected trajectory.

[0132] Step 802: derive the abnormal horizontal distance based on the product intersection coordinates and the detection hole position coordinates.

[0133] The abnormal horizontal distance is the horizontal distance between the intersection of the two balancing axes and the respective detection holes 31. This distance can be determined by calculating the distance between the intersection coordinates of the product and the detection hole locations. This can be done by establishing a parametric coordinate system on the horizontal plane and then mapping the coordinates of the two axes into this parametric coordinate system for calculation. Alternatively, the relative distance between the two axes can be measured on an image and converted to the actual abnormal horizontal distance based on the unit distance ratio on the image.

[0134] Step 803: Calculate the overlapping order based on the abnormal horizontal distance, the inclined horizontal length and the preset product length.

[0135] Because the diameter of inspection hole 31 is fixed and surrounded by a solid inner wall, one end of the balance shaft within inspection hole 31 must abut against the inner wall of inspection hole 31. Therefore, the length of the projection of the interior of inspection hole 31 on the horizontal plane is almost negligible, resulting in the length outside inspection hole 31 being considered the length of the balance shaft, i.e., the product length. A right triangle is then formed between the inclined horizontal length and the product length, with the product length as the hypotenuse and the inclined horizontal length as the right-angled side. The vertical inclination angle of the balance shaft is then determined, and the height of the product intersection coordinates is then determined based on the vertical inclination angle and the abnormal horizontal distance. The vertical order of the two is then determined based on the height.

[0136] Based on the same inventive concept, an embodiment of the present invention provides an intelligent terminal including a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and execute a balance shaft surface flaw detection method.

[0137] Those skilled in the art will clearly understand that for the sake of convenience and brevity, the division of the above-mentioned functional modules is only used as an example for illustration. In actual applications, the above-mentioned functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working processes of the above-mentioned systems, devices, and units can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0138] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for flaw detection on the surface of a balance shaft, characterized in that: include: Control the flaw detection device to execute the preset flaw detection program; When the flaw detection device detects a preset crack signal, the sensor number that sends the signal is obtained; Determining the electromagnet number in the corresponding detection hole (31) based on the issued sensor number; Controlling the electromagnet corresponding to the electromagnet number to be energized to fix the balancing shaft in the corresponding detection hole (31); Controlling a preset qualified tray (6) to move to the bottom of the detection rack (3); All the grippers (51) are controlled to execute a preset release command to control qualified products to fall into qualified trays (6).

2. A method for flaw detection on the surface of a balance shaft according to claim 1, characterized in that: Also includes: After completing the flaw detection procedure, obtain the number corresponding to the electromagnet number; When the number of serial numbers is less than the preset detection threshold, the flaw detection procedure is repeated until the number of serial numbers exceeds the detection threshold; When the number of numbers is greater than a preset detection quantity threshold, the qualified tray (6) is controlled to move out from under the base plate (1), and the unqualified tray (7) is controlled to move to under the detection rack (3); All electromagnets corresponding to the electromagnet numbers are controlled to be powered off, so that unqualified products fall into the unqualified tray (7).

3. A method for flaw detection on the surface of a balance shaft according to claim 2, characterized in that: Also includes: Determine the number of the unqualified gripper based on the electromagnet number; Determine the qualified gripper number based on the unqualified gripper number and the preset gripper number; After the flaw detection program is completed, the electromagnet corresponding to the electromagnet number is controlled to continue to be energized; The clamping jaw (51) corresponding to the qualified clamping jaw number is controlled to clamp the uninspected product on the preset uninspected tray (8), and is moved to the inspection rack (3) for inspection.

4. The method for flaw detection on the surface of a balance shaft according to claim 1, characterized in that: Also included is another method for controlling the clamping claw (51) to clamp the uninspected product on a preset uninspected tray (8) after executing the flaw detection program, the method comprising: Determine the number of qualified products based on the qualified gripper numbers; Determine the number of defective products based on the defective jaw numbers; Calculate the total mass of qualified products based on the number of qualified products and the preset weight of each product; Calculate the total weight of non-conforming products based on the number of non-conforming products and the weight of each product; After the qualified products fall into the qualified tray (6), the net weight of the qualified tray is obtained; When the net weight of the qualified pallet is equal to the total weight of the qualified products, the qualified pallet (6) is controlled to move out from under the inspection rack (3); Controlling the preset unqualified tray (7) to move to the bottom of the detection rack (3), and controlling the electromagnet corresponding to the electromagnet number to be powered off, so as to control the unqualified products to fall into the unqualified tray (7); Obtain the net weight of the non-conforming pallet of non-conforming products; When the net weight of the unqualified pallet is equal to the total weight of the unqualified products, all the grippers (51) are controlled to grip the untested products and continue to perform the flaw detection procedure.

5. The method for flaw detection on the surface of a balance shaft according to claim 3, characterized in that: The method of controlling the gripper (51) corresponding to the qualified gripper number to grip the untested product on the preset untested tray (8) and move it to the testing rack (3) for testing includes: After controlling the gripper (51) corresponding to the qualified gripper number to grip the uninspected product on the preset uninspected tray (8) and move it to the inspection rack (3), an inspection hole image is acquired based on the determined qualified gripper number; When the inspection hole image is consistent with the preset idle inspection hole image, the flaw detection procedure is repeatedly executed until the inspection hole image is inconsistent with the preset idle inspection hole image; When the detection hole image and the idle detection hole image are inconsistent, the qualified gripper number corresponding to the detection hole image is defined as the abnormal gripper number; Analyze the detection hole image of the abnormal gripper number to obtain the tilt angle and tilt horizontal length of the product corresponding to the abnormal gripper number relative to the vertical direction; Based on the abnormal gripper number, the corresponding detection hole position coordinates are found from the preset position database; Determine the correction trajectory for the angle correction of the product corresponding to the abnormal gripper number based on the tilt angle, the tilt horizontal length and the detection hole position coordinates; Controlling the clamping jaw (51) to move along the correction trajectory and continuing to acquire the detection hole image, and defining the detection hole image as the correction image; When the corrected image and the image of the idle inspection hole are consistent, the flaw detection procedure is repeated; When the corrected image and the image of the idle detection hole are inconsistent, the tilt angle and the correction trajectory are re-determined until the corrected image and the image of the idle detection hole are consistent.

6. A method for flaw detection on the surface of a balance shaft according to claim 5, characterized in that: Also included is a triggering method for acquiring an image of the detection hole, the method comprising: Control the untested product corresponding to the qualified gripper number to the corresponding detection hole position coordinate, move downward, and detect the current detection hole pressure; When the current detection hole pressure is equal to 0, continue to execute the flaw detection program until the current detection hole pressure is greater than 0; When the current detection hole pressure is greater than 0, the detection hole image is acquired.

7. The method for flaw detection on the surface of a balance shaft according to claim 5, characterized in that: The method of controlling the clamping jaw (51) to move along the correction trajectory includes: Obtain an overall bird's-eye view image; Determining an upper and lower interleaving trajectory and an upper and lower overlapping order based on the corrected trajectory; When interleaved trajectories exist, the correction order is determined based on the order of top-to-bottom overlap; Controlling the clamping jaws (51) to move in accordance with the correction trajectory in a correction order; When the staggered trajectory does not exist, the clamping jaw (51) is controlled to move according to any correction trajectory until all the correction top view images are consistent with the idle detection hole images.

8. The method for flaw detection on the surface of a balance shaft according to claim 7, characterized in that: The method for determining the staggered trajectory and the order of the staggered overlap based on the corrected trajectory includes: Delineate the contour lines based on the overall overhead image; Identify product intersection coordinates based on contour lines; The abnormal horizontal distance is obtained based on the product intersection coordinates and the detection hole position coordinates; The overlap order is calculated based on the abnormal horizontal distance, the inclined horizontal length and the preset product length.

9. A balance shaft surface flaw detection device, using a balance shaft surface flaw detection method according to any one of claims 1 to 8, characterized in that: include: A base plate (1) to provide a flaw detection platform; A fixing rod (2) connected to the base plate (1); A detection frame (3) is fixedly connected to the fixed rod (2) to provide a detection slot, and the detection frame (3) is provided with a detection hole (31) for the balance shaft to pass through for detection, the number of the detection holes (31) is several, and the inner side wall of the detection hole (31) is provided with an electromagnet; A rotating shaft (4) connected to the fixed rod (2); A mechanical arm (5) is fixedly connected to the rotating shaft (4), and the mechanical arm (5) is provided with a plurality of clamping claws (51) for clamping the balance shaft to move, and the clamping claws (51) and the detection holes (31) correspond one to one. The mechanical arm (5) is provided with a camera facing the detection hole (31), and the inner wall of the detection hole (31) is provided with a first pressure sensor for detecting the pressure in the detection hole (31); A qualified tray (6) is rotatably connected to the base plate (1) to receive qualified products dropped from the detection hole (31). A second pressure sensor for detecting the quality of qualified products is provided in the qualified tray (6). When the qualified tray (6) receives the qualified products, the qualified tray (6) is located below the detection frame (3); a non-conforming tray (7) rotatably connected to the base plate (1) to receive non-conforming products dropped from the detection hole (31); a third pressure sensor for detecting the quality of non-conforming products is provided in the non-conforming tray (7); when the non-conforming tray (7) receives the non-conforming products, the non-conforming tray (7) is located below the detection frame (3); and An uninspected tray (8) is fixedly connected to one side of the base plate (1) to place uninspected products.

10. An intelligent terminal, characterized in that: The method comprises a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executes the method according to any one of claims 1 to 8.

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