AI intelligent multi-specification small workpiece X-ray detection device

Abstract

The invention relates to an AI intelligent multi-specification small workpiece X-ray detection device which comprises a detection lead room, a matrix camera module, a mechanical arm moving mechanism, a multi-axis mechanical arm, a conveying assembly line, an imager, an imager supporting and adjusting mechanism, a ray machine, a ray machine supporting and adjusting mechanism, a correlation grating ruler, an outer protection lead cover, a protection lead curtain and an AI control center. The method comprises the following steps: performing three-dimensional modeling on a workpiece by adopting a structured light three-dimensional scanning technology, performing intelligent analysis on generated three-dimensional modeling digital data by combining data parameters of X-ray penetration thickness irradiation intensity and utilizing an AI intelligent calculation technology, performing intelligent calculation and analysis to obtain an optimal detection scheme, and completing intelligent ray detection of mixed small workpieces of multiple specifications. The detection efficiency is greatly improved, manual operation intervention is avoided, AI intelligent control is realized, an important step of enabling the nondestructive detection industry to advance towards high technology is realized, and the system is suitable for wide popularization.

Description

TECHNICAL FIELD

[0001] The patent relates to the field of X-ray nondestructive testing of small workpieces, in particular to an AI intelligent multi-specification small workpiece X-ray detection device and method. BACKGROUND

[0002] X-ray detection of small workpieces is currently a conventional detection technology, but for a variety of small workpieces mixed together with complex styles and changes, the detection technology is insufficient, the detection is cumbersome, and it is still in a semi-automatic detection state; the existing simple technology only performs plane scanning detection, the detection precision is not high, the detection angle position is not enough, and the detection requirements cannot be met; the existing semi-automatic detection technology needs to confirm the specific model of the workpiece and then correspondingly perform special position detection, the detection efficiency is low, manual screening of the workpiece is needed, and the workpiece needs to be detected separately; for a large number of mixed workpieces of various types, the detection efficiency is greatly reduced; the existing code scanning detection technology can detect the code after the code is punched on each workpiece, but the process of punching the code in advance needs to be increased, some workpieces have no position to punch the code in advance, and the code scanning is extremely difficult due to different positions of various types in the later scanning, and a large amount of database is needed as basic data for comparison, the detection efficiency is low, and the existing technology has improved the automation technology, but when dealing with mixed detection of small workpieces of various types and different shapes, it is difficult to punch the code in advance, it is difficult to scan the code before detection, it is difficult to compare the database, and the model needs to be screened one by one to determine the detection position and detection scheme of the individual workpiece, the automatic detection efficiency is extremely low, and it cannot meet the current production detection requirements. Moreover, the existing technology only stops at the automatic detection technology of the sensor, and is not a real AI intelligent detection, and a large amount of manual operation is needed for workpiece screening comparison, workpiece parameter database input, individual workpiece personalized detection position selection, detection result analysis, and detection. The detection efficiency is low. There is an urgent need for an AI intelligent detection device for complex and various specifications of small workpieces without code punching and detection scanning, and a highly intelligent and automatic detection device to quickly complete the detection work. SUMMARY

[0003] In order to solve the defects of the existing technology and truly realize AI intelligent detection, the patent provides an AI intelligent multi-specification small workpiece X-ray detection device, which comprises a detection lead house, a matrix camera module, a mechanical hand moving mechanism, a multi-axis mechanical hand, a conveying assembly line, an imager, an imager support adjusting mechanism, a ray machine, a ray machine support adjusting mechanism, a pair of light grating rulers, an outer protection lead cover, a protection lead curtain, and an AI control center.

[0004] A robotic arm moving mechanism is installed on the top frame of the lead testing room. Below the robotic arm moving mechanism, a multi-axis robotic arm is installed. An imager support and adjustment mechanism is installed on the front side wall in the middle of the lead testing room, with an imager installed at its front end. A X-ray machine support and adjustment mechanism is installed on the rear side wall in the middle of the lead testing room, with an X-ray machine installed at its front end. The X-ray receiving area of ​​the imager corresponds to the X-ray generating window of the X-ray machine on the same axis. A conveyor belt is installed in the middle of the lead testing room, with both ends of the conveyor belt extending out of the testing window of the lead testing room. External protective lead covers are installed on the outer sides of both ends of the testing window and in the space above the conveyor belt. A protective lead curtain is installed at the end of the lead shield. The protective lead room, the protective lead shield, and the protective lead curtain form a closed space. Multiple sets of matrix camera modules are evenly distributed in the middle of the inner side wall of the lead room, pointing towards the workpiece at the center of the conveyor line above the lead room from the side and diagonally, and scanning and modeling the workpiece. Multiple sets of matrix camera modules are evenly distributed in the middle top and bottom of the lead room, pointing towards the workpiece at the center of the conveyor line from the top and bottom, respectively, and scanning and modeling the workpiece. With the center of the conveyor line as the center point, through-beam grating rulers are symmetrically installed on the diagonal side wall inside the lead room for measuring and correcting the actual size of the workpiece. An AI control center is installed outside the lead room.

[0005] The lead testing room uses a steel frame as its skeleton, and protective lead plates are installed on the outside of the skeleton for radiation protection. The lead plates are fixed to the skeleton by welding thin steel plates on both sides with lead plates sandwiched in the middle.

[0006] The matrix camera module uses structured light 3D scanning technology to create a 3D model of the workpiece. It includes a high-definition camera, a flicker-free LED light, and a projector. The high-definition camera, flicker-free LED light, and projector are evenly and symmetrically distributed around the workpiece to be inspected, on the side walls, the roof, and the ground in the middle of the inspection room, forming a multi-dimensional central matrix module.

[0007] The conveyor system adopts a standard flexible belt conveyor system, which uses servo motors to control the transmission and precisely control the position of the conveyor.

[0008] The AI ​​control center is the core brain of this inspection device, including: industrial control computer center, automatic control module, modeling and calculation module, intelligent program calculation module, X-ray imaging processing module, and inspection image analysis module; all modules coordinate and work together to complete the entire process of intelligent X-ray inspection of the workpiece.

[0009] The moving mechanism of the manipulator adopts a linear guide rail slider for guiding, and a servo motor drives a gear rack for moving, thereby driving the multi-axis manipulator on the bearing in the transverse and longitudinal directions, and moving and positioning in the upper space of the lead house.

[0010] The multi-axis manipulator adopts standard robot arm technology, can bend the arm to contract the mechanical claw to grab the workpiece, and move and rotate the workpiece for scanning and detecting, including: two-claw clamps, three-claw clamps, special-shaped workpiece clamps, a mechanical hand seat, a manipulator rear arm, a manipulator middle arm, a manipulator rear arm, and a manipulator claw conversion seat. A mechanical hand seat is installed below the moving mechanism of the manipulator, a rotating bearing and a driving motor are arranged in the mechanical hand seat, and the mechanical hand seat can rotate. A manipulator rear arm is linked below the mechanical hand seat, is connected through a hinge, and can rotate and bend through motor driving. A manipulator middle arm is connected below the manipulator rear arm, is connected through a hinge, and can rotate and bend through motor driving. A manipulator rear arm is connected below the manipulator middle arm, is connected through a hinge, and can rotate and bend through motor driving. A manipulator claw conversion seat is connected to the lower end of the manipulator rear arm, a rotating bearing and a driving motor are arranged in the manipulator claw conversion seat, the manipulator claw conversion seat can be driven to rotate, and the lower end of the manipulator claw conversion seat is connected to the manipulator claw conversion seat. The front end of the manipulator claw conversion seat is a convertible spherical adjustment mechanism, and two-claw clamps, three-claw clamps, and special-shaped workpiece clamps are connected above the spherical adjustment mechanism. One set of clamps in the work is at the lowermost position, and the other two sets of clamps are uniformly distributed at both sides at a certain angle. According to the needs, the two sets of clamps can be automatically rotated and switched.

[0011] The LED non-flickering lamp uniformly transilluminates the grid-shaped light to the workpiece surface through the projector, the high-definition camera captures the workpiece at various angles, transmits the captured data to the AI control center for three-dimensional modeling, the light grating ruler measures the actual height of the workpiece, and transmits the measurement data to the AI control center for further size correction of the generated three-dimensional modeling, to obtain the final 1:1 modeling digital data of the actual workpiece.

[0012] The middle part of the middle plate and the frame of the conveying pipeline is a hollow structure, the material of the conveying belt of the conveying pipeline is transparent PVC material, and the matrix camera module can scan and model the lower contour of the workpiece through the conveying belt.

[0013] The mechanical claw of the front end of the multi-axis manipulator is an adjustable clamp that can be automatically converted, comprising: a two-claw clamp, a three-claw clamp, and a special-shaped workpiece clamp; the corresponding clamp is matched according to the detection of the workpiece profile, the long-shaped and square-shaped workpieces are matched with the two-claw clamp, the cylindrical workpieces and polygonal workpieces are matched with the three-claw clamp, and the slender and flat workpieces are matched with the special-shaped workpiece clamp. The spherical surface rotating structure of the mechanical claw of the front end of the multi-axis manipulator rotates the corresponding matched clamp to the lowest working position for work according to the shape of the workpiece. If the shape of the current workpiece to be detected does not match the clamp, the manipulator claw conversion seat is automatically rotated and adjusted to the corresponding matched clamp.

[0014] The control method of the AI control center comprises the following steps:

[0015] The industrial computer center serves as the core control center, and the system coordinates the orderly connection work of each module. The system communicates with the detection workers through the human-machine interface and stores various data collected during the detection.

[0016] The automatic control module is the driving control center of the device, which receives the overall collaborative control of the industrial computer center and is responsible for the transmission control of all operation actions, including: driving transmission driving control of the assembly line, driving transmission driving control of the mechanical hand moving mechanism bearing multi-axis manipulator horizontal and vertical adjustment, rotation and bending driving control of each joint of the multi-axis manipulator, and driving control of the adjustment and conversion of the front end air claw for clamping workpieces.

[0017] The modeling operation module receives the overall collaborative control of the industrial computer center, performs three-dimensional scanning of the workpiece from various angles through the matrix camera module, centrally models and operates multiple sets of scanning data pictures, synthesizes the three-dimensional model module of the workpiece, and then measures the actual height data of the workpiece through the light grating ruler, corrects it, and obtains the final three-dimensional modeling digital data of the actual workpiece 1:1.

[0018] The intelligent program operation module receives the overall cooperative control of the industrial computer center, intelligently analyzes the generated three-dimensional modeling digital data in the modeling operation module, analyzes the shape structure, size, and specific profile of the workpiece, combines the best detection imaging image size, ray intensity, penetration thickness, and image penetration angle position information provided by the ray imaging processing module, intelligently calculates and analyzes the optimal detection scheme, and the detection scheme includes: selection of grabbing mode, selection of three-jaw clamp for circular workpieces, selection of two-jaw clamp for square workpieces, selection of special-shaped workpiece clamp for slender and flat workpieces; selection of detection position, selection of the best penetration angle and movement step sequence according to the shape, size data, ray penetration thickness, and imaging area size of the workpiece; selection of ray intensity parameters, selection of appropriate ray tube current and voltage parameters according to the actual thickness and position information of the workpiece to determine the ray intensity; selection of movement steps: according to the previous grabbing position and imaging detection area, the entire workpiece position detection is completed by sequentially detecting the entire workpiece after parallel movement of the grabbed rectangular workpiece, or by sequentially rotating the workpiece after grabbing the cylindrical workpiece to complete the entire workpiece position detection, or by sequentially turning the workpiece after grabbing the special-shaped workpiece to complete the entire workpiece position detection. Finally, the optimal detection scheme is generated, and the operation result is sent to the industrial computer center.

[0019] The industrial computer center coordinates the linkage of other modules according to the optimal detection scheme, executes the detection scheme, drives the multi-axis robot to work, clamps the workpiece to the detection position, rotates and moves, and simultaneously starts the ray imaging processing module, opens the ray machine and imager to work and performs automatic X-ray detection. After detection, the ray is stopped and the workpiece is placed on the conveying line and conveyed out of the detection lead house.

[0020] The ray imaging processing module receives the overall cooperative control of the industrial computer center, transmits the ray intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the X-ray machine to the intelligent program operation module, calculates the optimal workpiece detection scheme, and opens the X-ray to adjust the input tube current and tube voltage of the ray machine according to the execution scheme, outputs the ray intensity of the execution scheme, synchronously opens the imager, accepts the X-ray passing through the workpiece for imaging detection, transmits the detection image information to the detection image analysis module, and closes the X-ray machine and imager according to the instruction after detection.

[0021] The detection image analysis module receives the overall cooperative control of the industrial computer center, receives the detection image information, processes the image through software, judges whether the detected workpiece meets the X-ray detection qualification standard requirements according to the contrast, sensitivity, and clarity requirements of the detection image, marks the qualified workpiece, and archives the detection data.

[0022] One of the detection methods of the AI intelligent multi-specification small workpiece X-ray detection device is as follows:

[0023] First step: the workpiece to be detected is conveyed to the conveying line, sequentially transmitted through the protective lead curtain and the outer protective lead cover to the middle of the detection lead house for positioning;

[0024] Second step: the AI control center starts working, the modeling operation module accepts the overall cooperative control of the industrial computer center, the matrix camera module performs structured light three-dimensional scanning on the workpiece from multiple angles such as the side, top and bottom, the LED non-flickering lamp uniformly transmits the grid-shaped light to the surface of the workpiece through the projector, the high-definition camera captures the workpiece from various angles, and the multiple sets of scanning data pictures are concentrated for modeling operation to synthesize the three-dimensional model module of the workpiece. Then, the actual height data of the workpiece is measured by the light grating ruler, corrected, and the final 1:1 three-dimensional modeling digital data of the actual workpiece is obtained.

[0025] Third step: the intelligent program operation module accepts the overall cooperative control of the industrial computer center, intelligently analyzes the three-dimensional modeling digital data generated in the modeling operation module, analyzes the shape structure, shape size and specific shape contour of the workpiece, and comprehensively analyzes the optimal detection scheme by combining the ray intensity information, corresponding penetration thickness information and detection sensitivity information provided by the ray imaging processing module. The optimal detection scheme is selected, including the grabbing mode, detection position, ray intensity parameter and motion step. The operation result is sent to the industrial computer center.

[0026] Fourth step: the industrial computer center cooperatively controls the ray imaging processing module, opens the input tube current and tube voltage of the X-ray adjusting ray machine according to the execution scheme, outputs the ray intensity of the execution scheme, synchronously opens the imager, and receives the X-ray passing through the workpiece for imaging detection.

[0027] Fifth step: the industrial computer center cooperatively controls the automatic control module according to the optimal scheme intelligently calculated, drives the mechanical hand moving mechanism to move, carries the multi-axis mechanical hand to the position directly above the workpiece, drives the multi-axis mechanical hand to automatically rotate and adjust the mechanical hand claw conversion seat, adjusts to the corresponding matched clamp, extends the front end claw clamp to grab the workpiece, and after the ray is synchronously opened, sequentially drives the workpiece to move in translation or rotate or flip according to the scheme, and after the detection is completed, returns the workpiece to the conveying line, closes the ray, drives the conveying line to convey the workpiece out of the detection lead house.

[0028] The beneficial technical effects are as follows: This invention solves the defects and shortcomings of the prior art and provides an AI intelligent X-ray inspection device for multi-specification small workpieces. It fundamentally solves the problem that the existing technology cannot efficiently inspect complex X-ray inspections of small workpieces with multiple specifications mixed together. Compared with traditional manual operation and intervention inspection, this device truly realizes AI intelligent operation throughout the entire process of inspection. It can complete the rapid inspection of various small workpieces mixed together, greatly improves the inspection efficiency, eliminates manual operation and intervention, realizes AI intelligent control, and achieves an important step for the non-destructive testing industry to advance towards high technology. It is suitable for widespread promotion. Attached Figure Description

[0029] Figure 1 This is the front view of the device;

[0030] Figure 2 This is a side view of the device;

[0031] Figure 3 This is a top view of the device;

[0032] In the diagram: 1. Lead inspection room; 2. Matrix camera module; 3. Robotic arm moving mechanism; 4. Multi-axis robotic arm; 5. Conveyor assembly line; 6. Imager; 7. Imager support and adjustment mechanism; 8. X-ray machine; 9. X-ray machine support and adjustment mechanism; 10. Through-beam grating ruler; 11. Outer protective lead cover; 12. Protective lead curtain; 13. AI control center; 14. Workpiece; 21. High-definition camera; 22. LED flicker-free light; 23. Projector; 41. Two-jaw gripper; 42. Three-jaw gripper; 43. Irregular workpiece gripper; 44. Mechanical handpiece holder; 45. Robotic arm rear arm; 46. Robotic arm intermediate arm; 47. Robotic arm rear arm; 48. Robotic gripper conversion seat; 51. Conveyor belt. Detailed Implementation

[0033] The preferred embodiments of this patent are described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely for explaining the technical principles of this patent and are not intended to limit the scope of protection of this patent.

[0034] An AI-powered intelligent X-ray inspection device for small workpieces of various sizes includes: a lead inspection room 1, a matrix camera module 2, a robotic arm moving mechanism 3, a multi-axis robotic arm 4, a conveyor line 5, an imager 6, an imager support and adjustment mechanism 7, an X-ray machine 8, an X-ray machine support and adjustment mechanism 9, a through-beam grating ruler 10, an outer protective lead cover 11, a protective lead curtain 12, and an AI control center 13.

[0035] The mechanical hand moving mechanism 3 is installed on the top end frame of the detection lead house 1, and the multi-axis mechanical hand 4 is installed below the mechanical hand moving mechanism 3. The imager support adjustment mechanism 7 is installed on the front side wall in the middle of the detection lead house 1, and the imager 6 is installed at the front end of the imager support adjustment mechanism 7 for accepting X-ray real-time imaging. The radiographic machine support adjustment mechanism 9 is installed on the rear side wall in the middle of the detection lead house 1, and the radiographic machine 8 is installed at the front end of the radiographic machine support adjustment mechanism 9 for generating emitted X-rays for imaging detection. The acceptance radiation area of the imager 6 corresponds to the radiation generation window of the radiographic machine 8 on the same axis. The conveying pipeline 5 is installed at the middle ground position of the detection lead house 1, and the two ends of the conveying pipeline 5 extend out of the detection window of the detection lead house 1. The outer protective lead cover 11 is installed at the space above the conveying pipeline 5 outside the two ends of the detection window of the detection lead house 1. The protective lead curtain 12 is installed at the end of the protective lead cover 11. The detection lead house 1, the protective lead cover 11 and the protective lead curtain 12 form a closed space to shield X-rays and avoid X-ray radiation outside the detection room. A plurality of groups of matrix camera modules 2 are uniformly distributed on the middle position of the inner side wall of the detection lead house 1 and respectively point to the workpiece 14 on the center of the conveying pipeline 5 from the lateral and oblique directions to scan and model the workpiece 14. A plurality of groups of matrix camera modules 2 are uniformly distributed on the middle top position and the bottom ground position inside the detection lead house 1 and respectively point to the workpiece 14 on the center of the conveying pipeline 5 from the top and bottom directions to scan and model the workpiece 14. The light barrier 10 is symmetrically arranged on the oblique side wall inside the detection lead house 1 with the center position of the conveying pipeline 5 as the center point for measuring and correcting the actual size of the workpiece 14. The AI control center 13 is installed outside the detection lead house 1.

[0036] The detection lead house 1 adopts a steel structure frame as a skeleton, and a protective lead plate is wrapped and installed outside the skeleton for radiation protection. The lead plate is fixed to the skeleton by welding in a manner that lead plates are sandwiched between two thin steel plates.

[0037] The matrix camera module 2 adopts a structured light three-dimensional scanning technology to perform three-dimensional modeling on the workpiece 14, including: a high-definition camera 21, an LED non-flickering lamp 22, and a projector 23. The high-definition camera 21, the LED non-flickering lamp 22, and the projector 23 are uniformly and symmetrically distributed around the center point of the workpiece 14 to be detected on the side wall, the top of the house, and the middle ground of the detection lead house 1, forming a surrounding multi-dimensional center matrix module.

[0038] The LED non-flickering lamp 22 uniformly transilluminates grid-shaped light to the surface of the workpiece through the projector 23, and the high-definition camera 21 captures the workpiece at various angles and transmits the captured data to the AI control center 13 for three-dimensional modeling.

[0039] Wherein the light emitting grating ruler 10 is selected as a standard high-precision measuring grating ruler, the actual height of the workpiece 14 is measured by scanning, and the measurement data is transmitted to the AI control center 13, the generated three-dimensional modeling is further corrected in size, and the final 1:1 modeling digital data of the actual workpiece is obtained.

[0040] Wherein the conveying pipeline 5 adopts a standard flexible belt conveying pipeline, and a servo motor is used to control the transmission and accurately control the conveying position. The middle plate and the middle part of the frame of the conveying pipeline 5 are hollow structures, so that the matrix camera module 2 below can scan and model the lower profile of the workpiece 14. The material of the conveying belt 51 of the conveying pipeline 5 is transparent PVC material, and the matrix camera module 2 can scan and model the lower profile of the workpiece 14 through the conveying belt 51.

[0041] Wherein the AI control center 13 is the core brain of the detection device, including: industrial computer center, automatic control module, modeling operation module, intelligent program operation module, ray imaging processing module, detection image analysis module; each module coordinates and links to complete the whole process of intelligent X-ray detection of the workpiece;

[0042] The control method of the AI control center 13 is as follows:

[0043] The industrial computer center is the core control center, and the system allocates each module to work in order. The system communicates with the detection workers through the man-machine interface, and stores various data in the detection.

[0044] The automatic control module is the driving control center of the device, which receives the overall cooperative control of the industrial computer center and is responsible for the transmission control of all operation actions, including: driving transmission driving control of the pipeline, driving transmission driving control of the mechanical hand moving mechanism 3, driving transmission driving control of the multi-axis mechanical hand 4, driving transmission driving control of each joint of the multi-axis mechanical hand 4, and driving control of the adjustment and conversion of the front end gas claw to clamp the workpiece.

[0045] The modeling operation module receives the overall cooperative control of the industrial computer center, and performs three-dimensional scanning on the workpiece 14 from various angles through the matrix camera module 2. The module is composed of a three-dimensional model of the workpiece 14 by concentrating and modeling a plurality of scanning data pictures, and the actual height data of the workpiece 14 is measured by scanning the light emitting grating ruler 10, corrected, and finally obtained 1:1 three-dimensional modeling digital data of the actual workpiece.

[0046] The intelligent program operation module receives the overall cooperative control of the industrial computer center, intelligently analyzes the generated three-dimensional modeling digital data in the modeling operation module, analyzes the shape structure, shape size, and specific shape contour of the workpiece 14, combines the best detection imaging image size, ray intensity, penetration thickness, and image penetration angle position information provided by the ray imaging processing module, intelligently calculates and analyzes the optimal detection scheme, and the detection scheme includes: selection of a grabbing mode, selection of a three-jaw clamp 42 for a circular workpiece, selection of a two-jaw clamp 41 for a square workpiece, selection of a special-shaped workpiece clamp 43 for an elongated or flat workpiece; selection of a detection position, selection of the best penetration angle and movement step sequence according to the shape, size data, ray penetration thickness, and imaging area size of the workpiece; selection of a ray intensity parameter, selection of appropriate ray tube current and voltage parameters according to the actual thickness and position information of the workpiece 14 to determine the ray intensity; selection of a movement step: according to the previous grabbing position and the detection area of the imaging, the entire workpiece position detection is completed by sequentially detecting the entire workpiece after parallel movement of the grabbed rectangular workpiece, or by sequentially detecting the entire workpiece after rotating the grabbed cylindrical workpiece, or by sequentially detecting the entire workpiece after flipping the grabbed special-shaped workpiece, and finally the optimal detection scheme is intelligently calculated and generated, and the operation result is sent to the industrial computer center.

[0047] The industrial computer center coordinates the linkage of other modules according to the optimal detection scheme, executes the detection scheme, drives the multi-axis robot 4 to work, clamps the workpiece 14 to the detection position, rotates and moves, and simultaneously starts the ray imaging processing module, turns on the ray machine 8 and the imager 6 to work and automatically performs X-ray detection. After the detection is completed, the ray is turned off and the workpiece 14 is placed on the conveying line 5 and conveyed out of the detection lead house 1.

[0048] The ray imaging processing module receives the overall cooperative control of the industrial computer center, transmits the ray intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the X-ray machine to the intelligent program operation module, calculates the optimal workpiece detection scheme, and according to the execution scheme, turns on the X-ray to adjust the input tube current and tube voltage of the ray machine 8, outputs the ray intensity of the execution scheme, synchronously turns on the imager 6, receives the X-ray passing through the workpiece for imaging detection, transmits the detection image information to the detection image analysis module, and according to the instruction, turns off the X-ray machine and the imager after the detection is completed.

[0049] The detection image analysis module receives the overall cooperative control of the industrial computer center, receives the detection image information, processes the image by software, judges whether the detected workpiece meets the X-ray detection qualified standard requirements according to the contrast requirement, sensitivity requirement, and definition requirement of the detection image, marks the qualified workpiece, and saves the detection data.

[0050] The mechanical hand moving mechanism 3 is guided by a linear guide rail slider, and a servo motor drives a gear rack to move, driving the multi-axis mechanical hand 4 on the upper bearing in the transverse and longitudinal directions, and moving and positioning in the upper space of the lead house 1.

[0051] The multi-axis mechanical hand 4 adopts standard robot arm technology, can bend the arm to contract the mechanical claw to grab the workpiece, and moves and rotates the workpiece to perform scanning detection work. It includes: two-claw clamp 41, three-claw clamp 42, special-shaped workpiece clamp 43, mechanical hand holder 44, mechanical hand rear arm 45, mechanical hand middle arm 46, mechanical hand rear arm 47, and mechanical hand claw conversion seat 48.

[0052] The mechanical hand holder 44 is installed below the mechanical hand moving mechanism 3, and a rotating bearing and a driving motor are arranged in the mechanical hand holder 44, which can rotate. The mechanical hand rear arm 45 is connected below the mechanical hand holder 44, and is connected through a hinge and can rotate and bend through motor driving. The mechanical hand middle arm 46 is connected below the mechanical hand rear arm 45, and is connected through a hinge and can rotate and bend through motor driving. The mechanical hand rear arm 47 is connected below the mechanical hand middle arm 46, and is connected through a hinge and can rotate and bend through motor driving. The mechanical hand claw conversion seat 48 is connected to the lower end of the mechanical hand rear arm 47, and a rotating bearing and a driving motor are arranged in the mechanical hand claw conversion seat 48, which can drive the mechanical hand claw conversion seat 48 connected below to rotate. The front end of the mechanical hand claw conversion seat 48 is a convertible spherical adjustment mechanism, and two-claw clamps 41, three-claw clamps 42, and special-shaped workpiece clamps 43 are connected above. One group of clamps in work is at the lowermost position, and the other two groups of clamps are uniformly distributed at both sides at a certain angle. According to needs, automatic rotation switching can be performed.

[0053] The mechanical claw at the front end of the multi-axis mechanical hand 4 is an adjustable clamp that can be automatically converted, including: two-claw clamps 41, three-claw clamps 42, and special-shaped workpiece clamps 43. According to the shape of the detected workpiece, the corresponding clamp is matched. Long-shaped and square-shaped workpieces are matched with two-claw clamps 41, cylindrical workpieces and polygonal workpieces are matched with three-claw clamps 42, and slender and flat workpieces are matched with special-shaped workpiece clamps 43. The spherical rotation structure of the mechanical claw at the front end of the multi-axis mechanical hand 4 rotates the corresponding matched clamp to the working position at the lowermost position according to the shape of the workpiece. If the shape of the current workpiece to be detected does not match the clamp, the mechanical hand claw conversion seat 48 is automatically rotated and adjusted to the corresponding matched clamp.

[0054] The detection method of the AI intelligent multi-specification small workpiece X-ray detection device is as follows:

[0055] First step: the workpiece 14 to be detected is conveyed to the conveying line 5, and then transmitted to the middle of the detection lead house 1 through the protective lead curtain 12 and the outer protective lead cover 11 for positioning;

[0056] Second step: the AI control center 13 starts to work, the modeling operation module accepts the overall cooperative control of the industrial computer center, the matrix camera module 2 performs structured light three-dimensional scanning on the workpiece 14 from multiple angles such as the side, top and bottom, the LED non-flickering lamp 22 uniformly transmits grid-shaped light to the surface of the workpiece through the projector 23, the high-definition camera 21 captures the workpiece at various angles, a plurality of sets of scanning data pictures are subjected to centralized modeling operation, a three-dimensional model module of the workpiece 14 is synthesized, the actual height data of the workpiece 14 is measured through the light grating ruler 10, correction is performed, and finally the three-dimensional modeling digital data of the workpiece 1:1 is obtained.

[0057] Third step: the intelligent program operation module accepts the overall cooperative control of the industrial computer center, intelligently analyzes the three-dimensional modeling digital data generated in the modeling operation module, analyzes the shape structure, shape size and specific shape contour of the workpiece 14, comprehensively analyzes the ray intensity information, corresponding penetration thickness information and detection sensitivity information provided by the ray imaging processing module, intelligently calculates and analyzes the optimal detection scheme, selects the grabbing mode, detection position, ray intensity parameter and movement step, and sends the operation result to the industrial computer center.

[0058] Fourth step: the industrial computer center cooperatively controls the ray imaging processing module, opens the input tube current and tube voltage of the X-ray adjusting ray machine 8 according to the execution scheme, outputs the ray intensity of the execution scheme, synchronously opens the imager 6, and receives the X-ray passing through the workpiece for imaging detection.

[0059] Fifth step: the industrial computer center cooperatively controls the automatic control module according to the optimal scheme intelligently calculated, drives the mechanical hand moving mechanism 3 to move, carries the multi-axis mechanical hand 4 to the position directly above the workpiece 14, drives the multi-axis mechanical hand 4 to automatically rotate and adjust the mechanical hand claw conversion seat 48, adjusts to the corresponding matched clamp, extends the front end claw clamp to grab the workpiece 14, and after the ray is synchronously opened, sequentially drives the workpiece to move in translation or rotate or flip according to the scheme, and after the detection is completed, returns the workpiece to the conveying line 5, closes the ray, and drives the conveying line 5 to convey the workpiece 14 out of the detection lead house 1.

[0060] Although the present patent has been described with reference to the preferred embodiments, various modifications and changes can be made to the present patent without departing from the scope of the present patent, and equivalents thereof, and the technical features mentioned in each of the embodiments can be combined in any manner, provided that there is no structural conflict, especially, the present patent is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

[0061] In the description of the present patent, the terms "upper", "lower", "left", "right", "horizontal", "inner", "outer" and the like indicating the direction or positional relationship are based on the direction or positional relationship shown in the drawings, which is merely for the convenience of description, and does not indicate or imply that the device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation of the present patent. In addition, the terms "first", "second", "third" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0062] In addition, it should be further pointed out that, in the description of the present patent, unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connection" should be understood broadly, for example, it can be fixed connection, or detachable connection, or integral connection; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through intermediate medium, or the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present patent can be understood according to the specific circumstances.

[0063] The above is only the preferred specific embodiment of the present application, but the protection scope of the present application is not limited thereto, any skilled person in the art can make equivalent replacement or change according to the technical solution and the inventive concept of the present application within the technical range disclosed by the present application, which should be covered in the protection scope of the present application.

Claims

1. An AI-powered intelligent X-ray inspection device for small workpieces of various specifications, characterized in that: include: The system includes a lead testing room, a matrix camera module, a robotic arm movement mechanism, a multi-axis robotic arm, a conveyor line, an imager, an imager support and adjustment mechanism, an X-ray machine, an X-ray machine support and adjustment mechanism, a through-beam grating ruler, an outer protective lead cover, a protective lead curtain, and an AI control center. The robotic arm movement mechanism is installed on the top frame of the lead testing room, and a multi-axis robotic arm is installed below it. An imager support and adjustment mechanism is installed on the front side wall of the lead testing room, with the imager mounted at its front end. An X-ray machine support and adjustment mechanism is installed on the rear side wall of the lead testing room, with the X-ray machine mounted at its front end. The X-ray receiving area of ​​the imager corresponds to the X-ray generating window of the X-ray machine on the same axis. A conveyor line is installed in the middle of the lead testing room, with both ends extending beyond the testing area of ​​the lead testing room. The inspection room has external protective lead covers installed at both ends of the inspection window and above the conveyor line. Protective lead curtains are installed at the ends of the protective lead covers. The inspection room, protective lead covers, and protective lead curtains form a closed space. Multiple sets of matrix camera modules are evenly distributed in the middle of the inner side wall of the inspection room, pointing towards the workpiece at the center of the conveyor line from the side and diagonally, and scanning and modeling the workpiece. Multiple sets of matrix camera modules are evenly distributed at the top and bottom of the inspection room, pointing towards the workpiece at the center of the conveyor line from the top and bottom, respectively, and scanning and modeling the workpiece. Symmetrical through-beam grating rulers are installed on the diagonal side wall of the inspection room, with the center of the conveyor line as the center point, to measure and correct the actual size of the workpiece. An AI control center is installed outside the inspection room. The lead testing room uses a steel frame as its skeleton, and protective lead plates are installed on the outside of the skeleton for radiation protection. The lead plates are fixed to the skeleton by welding thin steel plates on both sides with lead plates sandwiched in the middle. The matrix camera module uses structured light 3D scanning technology to create a 3D model of the workpiece. It includes a high-definition camera, a flicker-free LED light, and a projector. The high-definition camera, flicker-free LED light, and projector are evenly and symmetrically distributed around the workpiece to be inspected, on the side walls, the roof, and the ground in the middle of the inspection room, forming a multi-dimensional central matrix module. The conveyor system adopts a standard flexible belt conveyor system, which uses servo motors to control the transmission and precisely control the position of the conveyor. The AI ​​control center is the core brain of this inspection device, including: industrial control computer center, automatic control module, modeling and calculation module, intelligent program calculation module, X-ray imaging processing module, and inspection image analysis module; all modules coordinate and work together to complete the entire process of intelligent X-ray inspection of the workpiece. The robotic arm moving mechanism uses linear guide rails and sliders for guidance, and servo motors drive gears and racks for movement. It drives the multi-axis robotic arm on the upper part of the lead room in both horizontal and vertical directions to move and position itself in the upper space of the lead room. The multi-axis robotic arm employs standard robotic arm technology, capable of retracting and flexing its gripper to grasp workpieces and moving and rotating them for scanning and inspection. It includes: a two-jaw gripper, a three-jaw gripper, a shaped workpiece gripper, a robotic arm holder, a robotic arm rear arm, a robotic arm intermediate arm, and a robotic arm pneumatic gripper conversion base. The robotic arm holder is mounted below the robotic arm's moving mechanism, containing a rotary bearing and drive motor for rotational movement. The robotic arm rear arm is connected to the robotic arm holder via a hinge and is driven by a motor for rotational bending. The robotic arm intermediate arm is connected to the robotic arm rear arm via a hinge. The robot arm is connected to the rear arm via a hinge and can rotate and bend as driven by a motor. The lower end of the rear arm is connected to a gripper conversion seat. The rear arm contains a rotary bearing and a drive motor, which drives the gripper conversion seat to rotate. The front end of the gripper conversion seat has a convertible spherical adjustment mechanism, and it is equipped with a two-jaw gripper, a three-jaw gripper, and a gripper for irregularly shaped workpieces. One set of grippers is located at the bottom, and the other two sets of grippers are evenly distributed at a certain angle on both sides, automatically rotating and switching as needed.

2. The AI-powered intelligent X-ray inspection device for multi-specification small workpieces according to claim 1, characterized in that: The LED flicker-free light projector evenly illuminates the workpiece surface with a grid pattern. A high-definition camera captures images of the workpiece from various angles, and the captured data is transmitted to the AI ​​control center for 3D modeling. A through-beam grating ruler scans the workpiece to measure its actual height, and the measurement data is transmitted to the AI ​​control center for further dimensional correction of the generated 3D model, resulting in a final 1:1 model of the actual workpiece.

3. The AI-powered intelligent X-ray inspection device for multi-specification small workpieces according to claim 1, characterized in that: The middle tray and frame of the conveyor line have a hollow structure, and the conveyor belt of the conveyor line is made of transparent PVC material. The matrix camera module can scan and model the lower contour of the workpiece through the conveyor belt.

4. The AI-powered intelligent X-ray inspection device for multi-specification small workpieces according to claim 1, characterized in that: The multi-axis robot's front-end mechanical gripper is an automatically convertible and adjustable fixture, including: a two-jaw gripper, a three-jaw gripper, and an irregularly shaped workpiece gripper. The appropriate gripper is matched according to the shape of the workpiece being inspected: long and square workpieces are matched with two-jaw grippers, cylindrical and polygonal workpieces with three-jaw grippers, and slender and flat workpieces with irregularly shaped workpiece grippers. The spherical rotating structure of the multi-axis robot's front-end mechanical gripper rotates the corresponding gripper to the lowest working position according to the workpiece shape. If the shape of the workpiece to be inspected does not match the gripper, the robot's gripper conversion seat is automatically rotated and adjusted to the corresponding gripper.

5. The AI-powered intelligent X-ray inspection device for multi-specification small workpieces according to claim 1, characterized in that: The control methods of the AI ​​control center include: As the core control center, the industrial control computer center coordinates the various modules to work together in an orderly manner, communicates with the testing personnel through the human-machine interface, and summarizes and stores various data during the testing process. The automatic control module is the drive control center of this device. It receives overall coordinated control from the industrial control computer center and is responsible for the transmission control of all operation actions, including: the drive transmission control of the production line, the drive control of the horizontal and vertical adjustment of the multi-axis manipulator in the manipulator moving mechanism, the drive control of the rotation and bending of each joint of the multi-axis manipulator, and the drive control of the adjustment, conversion and workpiece gripping of the front-end pneumatic gripper. The modeling and calculation module receives overall collaborative control from the industrial control computer center. It performs structured light 3D scanning of the workpiece from various angles through the matrix camera module, performs centralized modeling and calculation on multiple sets of scan data images, synthesizes the 3D model module of the workpiece, and then scans the workpiece to measure the actual height data through the through-beam grating ruler, performs correction, and obtains the final 1:1 3D model digital data of the actual workpiece. The intelligent program calculation module receives overall collaborative control from the industrial control computer center. It intelligently analyzes the 3D modeling digital data generated in the modeling calculation module. By analyzing the workpiece's shape, dimensions, and specific contours, and combining this with the optimal detection image size, radiation intensity, penetration thickness, and image penetration angle provided by the X-ray imaging processing module, it intelligently calculates and analyzes the optimal detection scheme. The detection scheme includes: selection of the gripping method (three-jaw clamp for round workpieces, two-jaw clamp for square workpieces, and irregularly shaped workpiece clamp for slender and flat workpieces); and selection of the detection position based on the workpiece's shape, size, and radiation penetration thickness. The system determines the size of the imaging area, selects the optimal illumination angle and the sequence of movement steps; selects the X-ray intensity parameters based on the actual thickness and position information of the workpiece, choosing suitable X-ray tube current and voltage parameters to determine the X-ray intensity; selects the movement steps: based on the previous gripping position and the imaging detection area, it determines whether to grip a rectangular workpiece and move it parallel to complete the detection of all positions of the entire workpiece, or grip a cylindrical workpiece and rotate it sequentially to complete the detection of all positions of the entire workpiece, or grip an irregularly shaped workpiece and flip it sequentially to complete the detection of all positions of the entire workpiece. Finally, the system intelligently calculates the optimal detection scheme and sends the calculation results to the industrial control computer center. The industrial control computer center coordinates other modules according to the optimal detection plan, executes the detection plan, drives the multi-axis robot to work, picks up the workpiece to the detection position, and performs rotational and parallel movements. At the same time, the X-ray imaging processing module is started, and the X-ray machine and imager are turned on to perform automatic X-ray detection. After the detection is completed, the X-ray is turned off and the workpiece is placed on the conveyor line and sent out of the detection lead room. The X-ray imaging processing module receives overall collaborative control from the industrial control computer center. It transmits the X-ray intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the X-ray machine to the intelligent program calculation module. After calculating the optimal workpiece inspection plan, it turns on the X-ray machine, adjusts the input tube current and tube voltage, outputs the X-ray intensity of the execution plan, and simultaneously turns on the imager to receive X-rays passing through the workpiece for imaging inspection. It then transmits the inspection image information to the inspection image analysis module. After the inspection is completed, it turns off the X-ray machine imager according to the instructions. The detection image analysis module receives overall collaborative control from the industrial control computer center. After receiving the detection image information, it processes the image using software. Based on the requirements for contrast, sensitivity, and clarity of the detection image, it judges whether the workpiece meets the X-ray detection qualification standard. If it meets the standard, it is marked, and the detection data is archived and saved.

6. The AI-powered intelligent X-ray inspection device for multi-specification small workpieces according to claim 1, characterized in that: A detection method for an AI-powered intelligent X-ray inspection device for small workpieces of various sizes: Step 1: The workpiece to be inspected is conveyed to the conveyor line and passed through the protective lead curtain and outer protective lead cover in sequence to be positioned in the middle of the lead inspection room; Step 2: The AI ​​control center starts working. The modeling and calculation module receives overall collaborative control from the industrial control computer center. The matrix camera module performs structured light 3D scanning of the workpiece from multiple angles, including the side, top, and bottom. The LED flicker-free light projector evenly transmits grid-like light onto the workpiece surface. The high-definition camera captures images of the workpiece from various angles. Multiple sets of scanned images are centrally modeled and calculated to synthesize a 3D model module of the workpiece. Then, the workpiece is scanned and measured using a through-beam grating ruler to obtain the actual height data. After correction, the final 3D model digital data is obtained, which is 1:1 with the actual workpiece. Step 3: The intelligent program calculation module receives overall collaborative control from the industrial control computer center, and performs intelligent analysis on the 3D modeling digital data generated in the modeling calculation module. It analyzes the workpiece's shape structure, dimensions, and specific outline, and combines the X-ray intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the X-ray imaging processing module to perform comprehensive analysis. The intelligent calculation and analysis determine the optimal detection scheme, selects the gripping method, the detection position, the X-ray intensity parameters, and the motion steps, and sends the calculation results to the industrial control computer center. Step 4: The industrial control computer center coordinates with the X-ray imaging processing module to turn on the X-ray machine, adjust the input tube current and voltage of the X-ray machine according to the execution plan, output the X-ray intensity of the execution plan, and simultaneously turn on the imager to receive X-rays passing through the workpiece for imaging detection. Step 5: The industrial control computer center coordinates with the automatic control module to drive the robot arm moving mechanism according to the optimal scheme calculated by intelligent calculation. The robot arm is carried to a position directly above the workpiece. The robot arm is driven to automatically rotate and adjust the robot arm gripper conversion seat to the corresponding matching fixture. The front end gripper is extended to grab the workpiece. After the X-ray is turned on synchronously, the workpiece is driven to complete the translation, rotation or flipping movement according to the scheme. After the inspection is completed, the workpiece is returned to the conveyor line, the X-ray is turned off, and the conveyor line is driven to send the workpiece out of the inspection room.

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