Detection equipment and method for large casting

Abstract

The invention relates to the technical field of large casting detection, in particular to a large casting detection device and method. The large casting detection device comprises a detection lead room, a first moving frame, two second moving frames, a first six-axis robot, a second six-axis robot, an X-ray unit and a flat panel detector, the first six-axis robot drives the X-ray unit to move, and the second six-axis robot drives the X-ray unit to move; the second six-axis robot drives the flat panel detector to move, the vertical alignment relation between X-rays and the detector is kept, multi-angle dynamic scanning is achieved, the first moving frame in the detection lead room and the second moving frames on the two sides of the outer portion of the detection lead room are matched with the workpiece conveying trolley, a double-side alternate feeding and discharging system is formed, and parallel operation of detection and feeding and discharging is achieved. According to the technical scheme, the detection pose is flexibly adjusted through the robot, all-directional scanning of the casting can be completed through one-time clamping, the detection efficiency is remarkably improved, defects in a complex structure can be comprehensively captured, and the problems that a traditional method is insufficient in detection coverage and low in efficiency are solved.

Description

Technical Field

[0001] This invention relates to the field of large casting inspection technology, and in particular to an inspection device and method for large castings. Background Technology

[0002] Large castings are widely used in aerospace, energy equipment, heavy machinery, and automobile manufacturing, and their internal quality directly affects the safety and reliability of the products. During the casting process, due to factors such as material shrinkage, uneven cooling, or fluctuations in process parameters, defects such as porosity, shrinkage cavities, inclusions, and cracks are prone to occur inside the castings. Therefore, it is necessary to inspect the internal defects of large castings.

[0003] However, most traditional X-ray inspection systems use fixed X-ray sources and films or digital detectors, which can only acquire two-dimensional images of local areas through single-angle imaging. For large castings with complex structures or uneven thickness, the workpiece position or X-ray angle needs to be adjusted multiple times, resulting in low inspection efficiency and difficulty in covering all potential defect areas. Summary of the Invention

[0004] The purpose of this invention is to provide an inspection device and method for large castings, solving the problems of traditional X-ray inspection systems, which mostly use fixed X-ray sources and films or digital detectors, and can only acquire two-dimensional images of local areas through single-angle illumination. For large castings with complex structures or uneven thickness, multiple adjustments to the workpiece position or X-ray angle are required, resulting in low inspection efficiency and difficulty in covering all potential defect areas.

[0005] To achieve the above objectives, the present invention provides an inspection device for large castings. The inspection device includes an inspection lead chamber, a first movable frame, two second movable frames, a first six-axis robot, a second six-axis robot, an X-ray unit, and a flat panel detector. The first movable frame is horizontally arranged inside the inspection lead chamber, and the second movable frames are arranged on both sides of the exterior of the inspection lead chamber. A workpiece transport trolley is mounted on the first movable frame and one of the second movable frames. Each workpiece transport trolley is equipped with a workpiece clamping fixture. The first six-axis robot and the second six-axis robot are also installed inside the inspection lead chamber, located on opposite sides of the first movable frame. The X-ray unit is mounted on the output end of the first six-axis robot, and the flat panel detector is mounted on the output end of the second six-axis robot. The control systems of the first and second six-axis robots ensure that the output end of the X-ray unit and the receiving end of the flat panel detector are always perpendicular and located on opposite sides of the large casting to be inspected, which is fixed on the workpiece clamping fixture.

[0006] The X-ray unit includes a mounting base, two U-shaped mounting frames, two top pressure plates, an X-ray tube, and a beam collimator. The mounting base is installed at the output end of the first six-axis robot. The U-shaped mounting frames are provided on both sides of the side of the mounting base away from the output end of the first six-axis robot. The X-ray tube is installed between the grooves of the two U-shaped mounting frames. The top of each U-shaped mounting frame is fixed to the top of the top pressure plate by bolts. The beam collimator is provided between the ends of the two U-shaped mounting frames away from the mounting base. The output end of the X-ray tube corresponds to the beam collimator.

[0007] The mounting base has auxiliary mounting feet on both sides, and each auxiliary mounting foot is equipped with a cable routing support.

[0008] Each of the top pressure plates is provided with a X-ray tube limiting stage on the side facing the X-ray tube, and the side of the X-ray tube limiting stage away from the top pressure plate is provided with an arc-shaped groove, which is adapted to the outer wall of the X-ray tube.

[0009] Each of the workpiece clamping fixtures includes a fixture base, two sliding guide rails, two support frames, and two detachable workpiece clamps. The fixture base is mounted on the corresponding workpiece conveying trolley. Two sliding guide rails are symmetrically arranged laterally on the fixture base. Two support frames are slidably arranged between the two sliding guide rails. Each support frame has a detachable workpiece clamp at its top.

[0010] Each of the support frames includes a sliding base, two fixing screws, a support arm, and a mounting top plate. The mounting top plate is fixedly installed at one end of the support arm, and the sliding base is fixedly installed at the other end of the support arm. The sliding base slides between two sliding guide rails. Two fixing screws are provided on the sliding base, and multiple fixing holes are provided on each sliding guide rail. The fixing screws are adapted to the fixing holes.

[0011] Each of the sliding guide rails is equipped with a scale, and each of the sliding bases is equipped with a pointer, the pointer being compatible with the scale.

[0012] The lead testing room has side rooms on both sides, each side room has a protective door, and each side room has a second movable frame on the side away from the lead testing room.

[0013] This invention also provides a method for inspecting large castings, applied to the inspection equipment for large castings as described above, comprising the following steps: Based on the size and shape of the casting to be inspected, select the appropriate workpiece clamping fixture and install it on the workpiece conveying trolley. Then, retrieve the matching inspection program from the program library of the inspection equipment. The inspection program includes X-ray parameters, robot motion trajectory and scanning path. The casting to be tested is hoisted onto the workpiece conveying trolley of one of the second moving frames outside the testing lead room by an outer cantilever crane, and the position of the casting is fixed by the workpiece clamping fixture. Start the workpiece conveying trolley and send the workpiece conveying trolley carrying the casting from one side of the lead testing room into the first movable frame inside the lead testing room. At the same time, the empty workpiece conveying trolley on the first movable frame inside the lead testing room moves out of the lead testing room. The first six-axis robot and the second six-axis robot respectively drive the X-ray unit and the flat panel detector to the detection start position. The control system adjusts the spatial posture of the two in real time to ensure that the X-ray output end of the X-ray unit and the receiving end of the flat panel detector are always vertically aligned. The PLC controls the high-voltage generator to start the X-ray unit and emit X-rays according to preset parameters. After penetrating the casting, the X-rays are received by the flat panel detector. During the detection process, the robot moves continuously or stops in segments to complete multi-angle and multi-area scanning, covering all parts of the casting to be inspected. The flat panel detector converts the received X-ray signals into electrical signals, generates digital images after analog-to-digital conversion, and transmits them to a computer for defect identification and analysis, thus completing the inspection of large castings. After the large casting inspection is completed, the X-ray unit is turned off, the first six-axis robot and the second six-axis robot return to their origin positions, the workpiece transport trolley moves the inspected large casting out of the inspection lead room, and at the same time the workpiece transport trolley on the other side loads a new casting in, realizing continuous inspection.

[0014] This invention discloses an inspection device and method for large castings, comprising an inspection lead chamber, a first movable frame, two second movable frames, a first six-axis robot, a second six-axis robot, an X-ray unit, and a flat panel detector. The first six-axis robot drives the X-ray unit, and the second six-axis robot drives the flat panel detector. The two robots maintain the vertical alignment between the X-ray and the detector in real time through a high-precision collaborative control system, achieving multi-angle dynamic scanning. Furthermore, the first movable frame inside the inspection lead chamber and the second movable frames on both sides cooperate with the workpiece conveying trolley to form a double-sided alternating loading and unloading system, enabling parallel operation of inspection and loading / unloading. By adopting this technical solution, the robot can flexibly adjust its inspection posture, and a single clamping can complete an all-round scan of the casting, significantly improving inspection efficiency and comprehensively capturing defects inside complex structures, thus solving the problems of insufficient inspection coverage and low efficiency of traditional methods. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the structure of the testing equipment for large castings provided by the present invention.

[0017] Figure 2 This is a schematic diagram of the internal structure of the lead testing room provided by the present invention.

[0018] Figure 3 This invention provides Figure 2 A magnified view of the local structure at point A.

[0019] Figure 4 This is a schematic diagram of the workpiece clamping fixture provided by the present invention.

[0020] Figure 5 This invention provides Figure 4 A magnified view of the local structure at point B.

[0021] Figure 6 This is a flowchart of the steps of the detection method for large castings provided by the present invention.

[0022] 101-Lead inspection room; 102-First moving frame; 103-Second moving frame; 104-First six-axis robot; 105-Second six-axis robot; 106-Flat panel detector; 107-Workpiece transport trolley; 108-Mounting base; 109-U-shaped mounting frame; 110-Top pressure plate; 111-X-ray tube; 112-X-ray beam collimator; 113-Auxiliary mounting feet; 114-Cable routing support; 115-X-ray tube limiting platform; 116-Arc groove; 117-Tooling base; 118-Sliding guide rail; 119-Detachable workpiece clamp; 120-Sliding base; 121-Fixing screw; 122-Support arm; 123-Mounting top plate; 124-Fixing hole; 125-Scale; 126-Pointer; 127-Lifting lug; 128-Ear room; 129-Protective door. Detailed Implementation

[0023] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0024] Please see Figures 1 to 5 This invention provides an inspection device for large castings. The inspection device includes a lead inspection chamber 101, a first movable frame 102, two second movable frames 103, a first six-axis robot 104, a second six-axis robot 105, an X-ray unit, and a flat panel detector 106. The first movable frame 102 is horizontally arranged inside the lead inspection chamber 101, and the second movable frames 103 are arranged on both sides of the exterior of the lead inspection chamber 101. Workpiece transport trolleys 107 are mounted on the first movable frame 102 and one of the second movable frames 103. Each workpiece transport trolley 107 is equipped with a workpiece clamping fixture. The interior is also equipped with the first six-axis robot 104 and the second six-axis robot 105, which are located on both sides of the first moving frame 102. The output end of the first six-axis robot 104 is equipped with the X-ray unit, and the output end of the second six-axis robot 105 is equipped with the flat panel detector 106. The control system of the first six-axis robot 104 and the second six-axis robot 105 controls the output end of the X-ray unit and the receiving end of the flat panel detector 106 to always be in a perpendicular state, and are located on both sides of the large casting to be inspected fixed on the workpiece clamping fixture.

[0025] In this embodiment, the first six-axis robot 104 drives the X-ray unit to move, and the second six-axis robot 105 drives the flat panel detector 106 to move. The two robots maintain the vertical alignment between the X-ray and the detector in real time through a high-precision collaborative control system, realizing multi-angle dynamic scanning. Furthermore, the first moving frame 102 inside the detection lead room 101 and the second moving frames 103 on both sides of the exterior cooperate with the workpiece conveying trolley 107 to form a double-sided alternating loading and unloading system, realizing parallel operation of detection and loading / unloading. By adopting this technical solution, the robot can flexibly adjust the detection posture, and a full-range scanning of the casting can be completed in one clamping. This not only significantly improves the detection efficiency, but also comprehensively captures defects inside complex structures, solving the problems of insufficient detection coverage and low efficiency of traditional methods.

[0026] Furthermore, the X-ray unit includes a mounting base 108, two U-shaped mounting frames 109, two top pressure plates 110, an X-ray tube 111, and a beam collimator 112. The mounting base 108 is installed at the output end of the first six-axis robot 104. The U-shaped mounting frames 109 are provided on both sides of the side of the mounting base 108 away from the output end of the first six-axis robot 104. The X-ray tube 111 is installed between the grooves of the two U-shaped mounting frames 109. The top of each U-shaped mounting frame 109 is fixed to the top pressure plate 110 by bolts. The beam collimator 112 is provided between the ends of the two U-shaped mounting frames 109 away from the mounting base 108. The output end of the X-ray tube 111 corresponds to the beam collimator 112.

[0027] In this embodiment, the X-ray unit employs a double U-shaped mounting frame 109 in conjunction with the clamping design of the top pressure plate 110 to firmly fix the X-ray tube 111 onto the mounting base 108, effectively solving the technical problem that traditional fixing methods cannot support a 100 kg-class X-ray source. The design of the X-ray beam collimator 112 precisely aligning with the output end of the X-ray tube 111 ensures the collimation and penetration of the X-ray beam. Combined with the high-precision motion control of the six-axis robot, 450 kV high-energy X-rays can stably penetrate large castings and accurately image them. This modular mounting structure not only meets the detection requirements of ±90° large-angle rotation but also significantly reduces the vibration impact during robot movement through mechanical reinforcement, providing reliable hardware support for multi-angle, high-precision detection of complex casting structures.

[0028] Furthermore, auxiliary mounting feet 113 are provided on both sides of the mounting base 108, and a cable routing support 114 is provided on each of the auxiliary mounting feet 113.

[0029] In this embodiment, the dedicated cable routing support 114 enables standardized cable management, avoiding the risk of cable entanglement during robot movement.

[0030] Furthermore, each of the top pressure plates 110 is provided with a X-ray tube limiting stage 115 on the side facing the X-ray tube 111, and an arc-shaped groove 116 is provided on the side of the X-ray tube limiting stage 115 away from the top pressure plate 110, and the arc-shaped groove 116 is adapted to the outer side wall of the X-ray tube 111.

[0031] In this embodiment, the X-ray tube limiting platform 115 and its arc-shaped groove 116 provided on the top pressure plate 110 are designed to form a precise curved surface fit with the outer wall of the X-ray tube 111, which not only realizes the precise positioning of the X-ray tube 111, but also effectively disperses the impact force caused by equipment vibration by increasing the contact area.

[0032] Furthermore, each of the workpiece clamping fixtures includes a fixture base 117, two sliding guide rails 118, two support frames, and two detachable workpiece clamps 119. The fixture base 117 is mounted on the corresponding workpiece conveying trolley 107. Two sliding guide rails 118 are symmetrically arranged laterally on the fixture base 117. Two support frames are slidably arranged between the two sliding guide rails 118. Each support frame is provided with a detachable workpiece clamp 119 at its top.

[0033] In this embodiment, the symmetrically arranged double sliding guide rails 118 structure on the tooling base 117, together with the sliding support frame and the detachable clamp, realizes rapid adaptation and precise positioning of castings of different sizes and shapes. This not only ensures the stability of clamping large castings, but also allows for quick switching of the inspection object by adjusting the spacing of the support frame and changing the clamp, thus solving the problem of time-consuming tooling replacement in traditional methods.

[0034] Furthermore, each of the support frames includes a sliding base 120, two fixing screws 121, a support arm 122, and a mounting top plate 123. One end of the support arm 122 is fixedly provided with the mounting top plate 123, and the other end of the support arm 122 is fixedly provided with the sliding base 120. The sliding base 120 slides between two sliding guide rails 118. Two fixing screws 121 are provided on the sliding base 120. Each sliding guide rail 118 is provided with multiple fixing holes 124, and the fixing screws 121 are adapted to the fixing holes 124.

[0035] In this embodiment, the support frame adopts the cooperation mechanism of the sliding base 120 and the fixing screw 121, so that the support arm 122 can be accurately positioned along the sliding guide rail 118, and the distance between the two support frames can be adjusted by setting multiple fixing holes 124.

[0036] Furthermore, each of the sliding guide rails 118 is provided with a scale 125, and each of the sliding bases 120 is provided with a pointer 126, the pointer 126 being adapted to the scale 125.

[0037] In this embodiment, the setting of the scale 125 and the pointer 126 makes the adjustment of the position of the support frame more precise.

[0038] Furthermore, each of the four corners of the tooling base 117 is provided with a lifting lug 127.

[0039] In this embodiment, the lifting lug 127 facilitates the hoisting of the entire workpiece clamping fixture.

[0040] Furthermore, each side of the lead testing room 101 is provided with a side room 128, each side room 128 is provided with a protective door 129, and each side room 128 is provided with a second movable frame 103 on the side away from the lead testing room 101.

[0041] In this embodiment, the ear chamber 128 is a detachable structure, so that the lead detection chamber 101 can be disassembled during transportation to meet road width restriction requirements.

[0042] Please see Figure 6 The present invention also provides a method for inspecting large castings, applied to the inspection equipment for large castings as described above, comprising the following steps: S1: Select the appropriate workpiece clamping fixture according to the size and shape of the casting to be inspected, and install it on the workpiece conveying trolley 107. Retrieve the matching inspection program from the program library of the inspection equipment. The inspection program includes X-ray parameters, robot motion trajectory and scanning path. S2: The casting to be tested is hoisted onto the workpiece conveying trolley 107 of one of the second moving frames 103 outside the testing lead room 101 by an outer cantilever crane, and the position of the casting is fixed by the workpiece clamping fixture. S3: Start the workpiece conveying trolley 107 and send the workpiece conveying trolley 107 carrying the casting from one side of the lead inspection room 101 into the first movable frame 102 inside the lead inspection room 101. At the same time, the empty workpiece conveying trolley 107 on the first movable frame 102 inside the lead inspection room 101 moves out of the lead inspection room 101. S4: The first six-axis robot 104 and the second six-axis robot 105 respectively drive the X-ray unit and the flat panel detector 106 to the detection start position. The control system adjusts the spatial posture of the two in real time to ensure that the X-ray output end of the X-ray unit and the receiving end of the flat panel detector 106 are always vertically aligned. S5: The PLC controls the high voltage generator to start the X-ray unit and emit X-rays according to preset parameters. After penetrating the casting, the X-rays are received by the flat panel detector 106. During the detection process, the robot continuously moves or pauses in segments to complete multi-angle and multi-area scanning, covering all parts of the casting to be inspected. S6: The flat panel detector 106 converts the received X-ray signal into an electrical signal, generates a digital image after analog-to-digital conversion, and transmits it to a computer for defect identification and analysis, thus completing the inspection of large castings; S7: After the current large casting inspection is completed, the X-ray unit is turned off, the first six-axis robot 104 and the second six-axis robot 105 return to the origin position, the workpiece transport trolley 107 moves the inspected large casting out of the inspection lead room 101, and at the same time the workpiece transport trolley 107 on the other side loads a new casting in to achieve continuous inspection.

[0043] In this embodiment, the automatic alignment and multi-angle scanning of the X-ray unit and the flat panel detector 106 are achieved through programmed control, ensuring that there are no blind spots in the detection; a dual-side conveying system is adopted to realize parallel operation of detection and loading / unloading, thereby improving equipment utilization; at the same time, the workpiece clamping fixture can meet the needs of castings of different specifications, thereby improving the applicability of the equipment.

[0044] The above description discloses only one preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Those skilled in the art will understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A testing device for large castings, characterized in that, The system includes a lead inspection room, a first movable frame, two second movable frames, a first six-axis robot, a second six-axis robot, an X-ray unit, and a flat panel detector. The first movable frame is horizontally arranged inside the lead inspection room, and the second movable frames are located on both sides of the exterior of the lead inspection room. Each of the first movable frame and one of the second movable frames is equipped with a workpiece transport trolley, and each workpiece transport trolley is equipped with a workpiece clamping fixture. The first and second six-axis robots are also installed inside the lead inspection room, located on opposite sides of the first movable frame. The X-ray unit is installed at the output end of the first six-axis robot, and the flat panel detector is installed at the output end of the second six-axis robot. The control systems of the first and second six-axis robots ensure that the output end of the X-ray unit and the receiving end of the flat panel detector are always perpendicular and located on opposite sides of the large casting to be inspected, which is fixed on the workpiece clamping fixture.

2. The testing equipment for large castings as described in claim 1, characterized in that, The X-ray unit includes a mounting base, two U-shaped mounting frames, two top pressure plates, an X-ray tube, and a beam collimator. The mounting base is installed at the output end of the first six-axis robot. The U-shaped mounting frames are provided on both sides of the side of the mounting base away from the output end of the first six-axis robot. The X-ray tube is installed between the grooves of the two U-shaped mounting frames. The top pressure plate is fixed to the top of each U-shaped mounting frame by bolts. The beam collimator is provided between the ends of the two U-shaped mounting frames away from the mounting base. The output end of the X-ray tube corresponds to the beam collimator.

3. The testing equipment for large castings as described in claim 2, characterized in that, The mounting base is provided with auxiliary mounting feet on both sides, and each of the auxiliary mounting feet is provided with a cable routing support.

4. The testing equipment for large castings as described in claim 3, characterized in that, Each of the top pressure plates is provided with a X-ray tube limiting stage on the side facing the X-ray tube, and the side of the X-ray tube limiting stage away from the top pressure plate is provided with an arc-shaped groove, which is adapted to the outer wall of the X-ray tube.

5. The testing equipment for large castings as described in claim 4, characterized in that, Each workpiece clamping fixture includes a fixture base, two sliding guide rails, two support frames, and two detachable workpiece clamps. The fixture base is mounted on the corresponding workpiece conveying trolley. Two sliding guide rails are symmetrically arranged laterally on the fixture base. Two support frames are slidably arranged between the two sliding guide rails. Each support frame has a detachable workpiece clamp at its top.

6. The testing equipment for large castings as described in claim 5, characterized in that, Each of the support frames includes a sliding base, two fixing screws, a support arm, and a mounting top plate. The mounting top plate is fixedly mounted on one end of the support arm, and the sliding base is fixedly mounted on the other end of the support arm. The sliding base slides between two sliding guide rails. Two fixing screws are provided on the sliding base, and multiple fixing holes are provided on each sliding guide rail. The fixing screws are adapted to the fixing holes.

7. The testing equipment for large castings as described in claim 6, characterized in that, Each of the sliding guide rails is equipped with a scale, and each of the sliding bases is equipped with a pointer, the pointer being adapted to the scale.

8. The testing equipment for large castings as described in claim 7, characterized in that, The lead testing room has side rooms on both sides, each side room has a protective door, and each side room has a second movable frame on the side away from the lead testing room.

9. A method for inspecting large castings, applied to the inspection equipment for large castings as described in claim 1, characterized in that, Includes the following steps: Based on the size and shape of the casting to be inspected, select the appropriate workpiece clamping fixture and install it on the workpiece conveying trolley. Then, retrieve the matching inspection program from the program library of the inspection equipment. The inspection program includes X-ray parameters, robot motion trajectory and scanning path. The casting to be tested is hoisted onto the workpiece conveying trolley of one of the second moving frames outside the testing lead room by an outer cantilever crane, and the position of the casting is fixed by the workpiece clamping fixture. Start the workpiece conveying trolley and send the workpiece conveying trolley carrying the casting from one side of the lead testing room into the first movable frame inside the lead testing room. At the same time, the empty workpiece conveying trolley on the first movable frame inside the lead testing room moves out of the lead testing room. The first six-axis robot and the second six-axis robot respectively drive the X-ray unit and the flat panel detector to the detection start position. The control system adjusts the spatial posture of the two in real time to ensure that the X-ray output end of the X-ray unit and the receiving end of the flat panel detector are always vertically aligned. The PLC controls the high-voltage generator to start the X-ray unit and emit X-rays according to preset parameters. After penetrating the casting, the X-rays are received by the flat panel detector. During the detection process, the robot moves continuously or stops in segments to complete multi-angle and multi-area scanning, covering all parts of the casting to be inspected. The flat panel detector converts the received X-ray signals into electrical signals, generates digital images after analog-to-digital conversion, and transmits them to a computer for defect identification and analysis, thus completing the inspection of large castings. After the large casting inspection is completed, the X-ray unit is turned off, the first six-axis robot and the second six-axis robot return to their origin positions, the workpiece transport trolley moves the inspected large casting out of the inspection lead room, and at the same time the workpiece transport trolley on the other side loads a new casting in, realizing continuous inspection.

Images