Detection system based on metal product processing

Abstract

The invention relates to the technical field of processing detection, and particularly discloses a detection system based on metal product processing, which is provided with a qualified machine screening module, an appearance state qualified metal product screening module and a qualified metal product screening module. The problems that traditional detection of metal product machining is limited to finished product appearance monitoring of metal products, and detection of metal product machining is not comprehensive in consideration are solved, potential fault signs can be found in advance through monitoring and analysis of machine operation state data, preventive maintenance can be carried out, the maintenance cost is reduced, and the working efficiency is improved. And qualified machines are screened out to work, stable equipment operation is ensured, the product quality problem caused by machine faults or abnormity is effectively avoided, the metal products with qualified appearance states represent the attention and strict control of enterprises on the product quality, the abnormal conditions of the metal products can be detected more accurately through infrared thermal imaging, and the production efficiency is improved. And measures are taken in time to repair or reject unqualified products.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of processing detection, in particular to a detection system based on metal product processing. BACKGROUND

[0002] With the development of manufacturing industry towards intelligence and automation, the metal product processing process needs to be highly automated and intelligent. In order to improve production efficiency, reduce production cost and improve product quality, a more intelligent and comprehensive detection system needs to be developed to monitor and control the metal product processing process. The processing quality of metal products directly affects the performance and reliability of products. Poor processing quality will lead to unqualified products, causing waste and loss. A high-precision and high-efficiency detection system needs to be developed to ensure the quality control in the metal product processing process.

[0003] Nowadays, there are still some deficiencies in the research on a detection system based on metal product processing. Specifically, the traditional detection of metal product processing is limited to monitoring the appearance of finished metal products. The detection of metal product processing is not comprehensive enough. If there is a quality problem or abnormality in the processing process, the opportunity for timely correction may be missed, leading to an increase in the production of defective products. It is also impossible to fully reflect the details and changes in the processing process. The traditional detection of finished product appearance often relies on manual visual inspection or simple sensor technology, lacking intelligent and data-driven capabilities. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application provides a detection system based on metal product processing, which can effectively solve the problems involved in the background art.

[0005] To achieve the above purpose, the present application realizes the following technical scheme: a detection system based on metal product processing, comprising a qualified machine screening module, an appearance state qualified metal product screening module and a qualified metal product screening module, wherein: the qualified machine screening module obtains a machine running state data set required for metal product processing, and screens qualified machines based on the obtained machine running state data set required for metal product processing; the appearance state qualified metal product screening module obtains a metal product appearance state data set processed by the qualified machine, and screens metal products with qualified appearance state based on the obtained metal product appearance state data set processed by the qualified machine; the qualified metal product screening module performs preheating treatment on the metal products with qualified appearance state, obtains an infrared thermal imaging state data set of the metal products with qualified appearance state, and screens qualified metal products based on the obtained infrared thermal imaging state data set of the metal products with qualified appearance state.

[0006] As a further solution, the metal product processing required machine running state data set specifically includes the metal product processing required machine running vibration frequency, the metal product processing required machine running surface maximum temperature, and the metal product processing required machine running process lubricating oil oil pressure.

[0007] As a further solution, based on the obtained metal product processing required machine running state data set, the qualified machine is screened, and the specific analysis process is as follows: based on the obtained metal product processing required machine running state data set, a comprehensive analysis is performed to obtain a metal product processing required machine running state evaluation value, which serves as the analysis basis for screening the qualified machine; the metal product processing required machine running state evaluation value is compared with the metal product processing required machine running state reference evaluation value stored in the database; if the metal product processing required machine running state evaluation value is higher than or equal to the metal product processing required machine running state reference evaluation value, the metal product processing required machine running state evaluation value corresponds to a qualified metal product processing required machine running state, and the metal product processing required machine is marked as a qualified machine; if the metal product processing required machine running state evaluation value is lower than the metal product processing required machine running state reference evaluation value, the metal product processing required machine running state evaluation value corresponds to an unqualified metal product processing required machine running state, and the metal product processing required machine is marked as an unqualified machine and an unqualified alarm is issued for the unqualified machine.

[0008] As a further solution, the metal product processing required machine running state evaluation value is specifically analyzed as follows:

[0009]

[0010] In the formula, γ is the metal product processing required machine running state evaluation value, ZD is the metal product processing required machine running vibration frequency, T is the metal product processing required machine running surface maximum temperature, RY is the metal product processing required machine running process lubricating oil oil pressure, ZD0 is the metal product processing required machine running reference vibration frequency stored in the database, T0 is the metal product processing required machine running surface maximum reference temperature stored in the database, RY0 is the metal product processing required machine running process lubricating oil reference oil pressure stored in the database, θ1 is the set compensation factor of the metal product processing required machine running vibration frequency, θ2 is the set compensation factor of the metal product processing required machine running surface maximum temperature, θ3 is the set compensation factor of the metal product processing required machine running process lubricating oil oil pressure, and e is the natural constant.

[0011] As a further solution, the appearance state data set of the qualified machine-processed metal product specifically includes the number of cracks exceeding a defined length of the qualified machine-processed metal product, the number of bubbles exceeding a defined area of the qualified machine-processed metal product, and the maximum indentation depth of the qualified machine-processed metal product.

[0012] As a further solution, based on the obtained appearance state data set of the qualified machine-processed metal product, the metal product with a qualified appearance state is screened, and the specific analysis process is as follows: based on the obtained appearance state data set of the qualified machine-processed metal product, a comprehensive analysis is performed to obtain an appearance state evaluation value of the qualified machine-processed metal product, which serves as the analysis basis for screening the metal product with a qualified appearance state; the appearance state evaluation value of the qualified machine-processed metal product is compared with the reference evaluation value of the appearance state of the qualified machine-processed metal product stored in the database; if the appearance state evaluation value of the qualified machine-processed metal product is higher than or equal to the reference evaluation value of the appearance state of the qualified machine-processed metal product, the metal product corresponding to the appearance state evaluation value of the qualified machine-processed metal product is marked as the metal product with a qualified appearance state; if the appearance state evaluation value of the qualified machine-processed metal product is lower than the reference evaluation value of the appearance state of the qualified machine-processed metal product, the metal product corresponding to the appearance state evaluation value of the qualified machine-processed metal product is marked as the metal product with an unqualified appearance state.

[0013] As a further solution, the appearance state evaluation value of the qualified machine-processed metal product is specifically analyzed as follows:

[0014]

[0015] In the formula, δ is the appearance state evaluation value of the qualified machine-processed metal product, LF is the number of cracks exceeding a defined length of the qualified machine-processed metal product, QP is the number of bubbles exceeding a defined area of the qualified machine-processed metal product, OX is the maximum indentation depth of the qualified machine-processed metal product, LF0 is the permitted number of cracks exceeding a defined length of the qualified machine-processed metal product stored in the database, QP0 is the permitted number of bubbles exceeding a defined area of the qualified machine-processed metal product stored in the database, OX0 is the permitted indentation depth of the qualified machine-processed metal product stored in the database, μ1 is a compensation factor set for the number of cracks exceeding a defined length of the qualified machine-processed metal product, μ2 is a compensation factor set for the number of bubbles exceeding a defined area of the qualified machine-processed metal product, and μ3 is a compensation factor set for the maximum indentation depth of the qualified machine-processed metal product.

[0016] As a further solution, the infrared thermal imaging state data set of the appearance state qualified metal product specifically includes the maximum surface temperature difference of the appearance state qualified metal product, the number of temperature abnormal regions of the appearance state qualified metal product, and the temperature change rate of the appearance state qualified metal product.

[0017] As a further solution, based on the obtained infrared thermal imaging state data set of the appearance state qualified metal product, the qualified metal product is screened, and the specific analysis process is as follows: based on the obtained infrared thermal imaging state data set of the appearance state qualified metal product, an infrared thermal imaging state evaluation value of the appearance state qualified metal product is obtained through comprehensive analysis, the infrared thermal imaging state evaluation value of the appearance state qualified metal product is used as the analysis basis for screening the qualified metal product; the infrared thermal imaging state evaluation value of the appearance state qualified metal product is compared with the infrared thermal imaging state reference evaluation value of the appearance state qualified metal product stored in the database; if the infrared thermal imaging state evaluation value of the appearance state qualified metal product is higher than or equal to the infrared thermal imaging state reference evaluation value of the appearance state qualified metal product, the appearance state qualified metal product corresponding to the infrared thermal imaging state evaluation value of the appearance state qualified metal product is marked as a qualified metal product; if the infrared thermal imaging state evaluation value of the appearance state qualified metal product is lower than the infrared thermal imaging state reference evaluation value of the appearance state qualified metal product, the appearance state qualified metal product corresponding to the infrared thermal imaging state evaluation value of the appearance state qualified metal product is marked as an unqualified metal product.

[0018] As a further solution, the infrared thermal imaging state evaluation value of the appearance state qualified metal product is specifically analyzed as follows:

[0019]

[0020] In the formula, ω is the infrared thermal imaging state evaluation value of the appearance state qualified metal product, WC is the maximum surface temperature difference of the appearance state qualified metal product, WY is the number of temperature abnormal regions of the appearance state qualified metal product, WB is the temperature change rate of the appearance state qualified metal product, WC0 is the surface temperature defined difference of the appearance state qualified metal product stored in the database, WY0 is the number of temperature abnormal defined regions of the appearance state qualified metal product stored in the database, WB0 is the reference temperature change rate of the appearance state qualified metal product stored in the database, σ1 is the compensation factor of the maximum surface temperature difference of the appearance state qualified metal product, σ2 is the compensation factor of the number of temperature abnormal regions of the appearance state qualified metal product, σ3 is the compensation factor of the temperature change rate of the appearance state qualified metal product, and e is the natural constant.

[0021] Compared with the prior art, the embodiments of the present application have at least the following advantages or benefits: (1) The present application provides a detection system based on metal product processing. By obtaining the machine operating state data set required for metal product processing, the qualified machines are screened, and the abnormal behavior or fault condition of the machine can be found in time. The abnormal machines are screened and repaired, which helps to reduce the production downtime, improve the production efficiency, and through the monitoring and analysis of the machine operating state data, potential failure signs can be found in advance, preventive maintenance can be performed, maintenance costs can be reduced, the service life of the equipment can be prolonged, qualified machines can be screened for work, the equipment operation can be ensured stable, product quality problems caused by machine failure or abnormality can be effectively avoided, and the product quality can be ensured to meet the quality standards.

[0022] (2) The present application can ensure that only products with standard appearance are released to the market, which helps to improve product quality, enhance enterprise image, and enhance product competitiveness. The rate of defective products and rework can be reduced, the quality risk related to products can be reduced, enterprise costs can be saved, and the appearance of qualified metal products represents the importance and strict control of the enterprise on product quality, which helps to enhance brand value and credibility, increase consumer trust and loyalty to the brand.

[0023] (3) The present application screens qualified metal products by preheating the metal products with standard appearance. Preheating can homogenize the internal temperature of the metal products and reduce the thermal imaging result error caused by uneven temperature. In this way, the defects or abnormal conditions of the metal products can be more accurately detected by infrared thermal imaging. Preheating can make the metal products reach the required temperature before entering the thermal imaging equipment, reduce the waiting time during thermal imaging, and thus improve the efficiency and throughput of the production line. Through preheating, the energy required during thermal imaging can be reduced because the metal products have been preheated to a certain temperature, reducing the energy consumption of the thermal imaging equipment. By more accurately detecting the defects or abnormal conditions of the metal products, measures can be taken in time to repair or reject unqualified products, thereby reducing the scrap rate and production cost. BRIEF DESCRIPTION OF DRAWINGS

[0024] The present application is further described with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present application. For ordinary skilled persons in the art, other drawings can be obtained without creative labor on the basis of the following drawings.

[0025] Figure 1 The present application is further described with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present application. For ordinary skilled persons in the art, other drawings can be obtained without creative labor on the basis of the following drawings.

[0026] Figure 2 The present application is further described with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present application. For ordinary skilled persons in the art, other drawings can be obtained without creative labor on the basis of the following drawings. DETAILED DESCRIPTION

[0027] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0028] Please refer to Figure 1 The embodiment of the present application provides a detection technical scheme based on metal product processing: a detection system based on metal product processing, comprising a qualified machine screening module, an appearance state qualified metal product screening module and a qualified metal product screening module.

[0029] The qualified machine screening module is used to obtain a machine running state data set required for metal product processing, and screen qualified machines based on the obtained machine running state data set required for metal product processing.

[0030] Specifically, the machine running state data set required for metal product processing specifically includes a machine running vibration frequency required for metal product processing, a machine running surface maximum temperature required for metal product processing, a machine running process lubricating oil oil pressure required for metal product processing, the machine running vibration frequency refers to the vibration frequency generated by the machine equipment in the metal product processing process, appropriate vibration frequency can effectively help the metal product to reduce materials or form in the processing process, improve processing efficiency and processing quality, too high or too low vibration frequency may cause equipment imbalance, reduce processing precision or produce quality problems, the machine running surface maximum temperature refers to the maximum temperature allowed to be reached by the surface of the machine equipment in the metal product processing process, metal product processing involves high-temperature hot processing, cutting, cooling and other processes, controlling the maximum temperature of the machine surface can ensure the normal operation of the equipment and not damaged, avoid overheating accidents or affect the processing quality, the machine running process lubricating oil oil pressure refers to the oil pressure required to be maintained by the lubricating system of the machine equipment in the metal product processing process, lubricating oil is a commonly used lubricant in metal processing process, which can reduce friction and wear, improve processing quality and efficiency, appropriate lubricating oil oil pressure can ensure the normal operation of the machine, reduce machine wear and damage, and improve equipment life.

[0031] It should be noted that the aforementioned appropriate lubricating oil can reduce friction and wear between machine parts, help lower vibration frequency, reduce machine vibration, and improve operational stability. At the same time, lubricating oil can also help dissipate heat, lower the maximum temperature of the machine surface, and prevent overheating. Vibration frequencies that are too high or too low will affect the operational stability and temperature control of the machine equipment, potentially causing the surface temperature to exceed the range, leading to equipment damage or decreased processing quality, and increased friction and wear. An appropriate vibration frequency can effectively improve processing efficiency, reduce temperature, and maintain appropriate lubricating oil pressure. An excessively high surface temperature will affect the operational stability and vibration frequency of the equipment, potentially leading to overheating and increased vibration. An appropriate surface temperature can maintain a stable vibration frequency, reduce friction and wear, and lower the lubricating oil pressure requirements.

[0032] Specifically, based on the acquired dataset of machine operating statuses required for metal product processing, qualified machines are screened. The specific analysis process is as follows: Based on the acquired dataset of machine operating statuses required for metal product processing, a comprehensive analysis is conducted to obtain the machine operating status evaluation value. This evaluation value serves as the basis for screening qualified machines. The machine operating status evaluation value is compared with the reference evaluation value stored in the database. If the machine operating status evaluation value is higher than or equal to the reference evaluation value, the machine operating status corresponding to that evaluation value is qualified, and the machine is marked as qualified. If the machine operating status evaluation value is lower than the reference evaluation value, the machine operating status corresponding to that evaluation value is unqualified, and the machine is marked as unqualified, and an unqualified alarm is issued.

[0033] It should be noted that the above methods can promptly identify qualified machines with high operating conditions, thereby improving production efficiency. Qualified machines operate stably and well, ensuring smooth processing, reducing downtime, and increasing production efficiency. Assessing machine operating conditions allows for the early detection of problematic machines, enabling timely maintenance and preventing malfunctions. Qualified machines are typically in good condition, requiring less frequent repairs and reducing maintenance costs. Their good operating condition ensures product quality, reducing defect rates caused by machine problems. By screening out qualified machines, the stability and consistency of product quality can be guaranteed. Assessing the operating conditions of machines required for metal product processing allows for the timely identification of machines with potential safety hazards, ensuring safe production. Qualified machines operate stably and reliably, reducing the probability of safety accidents. Screening out qualified machines improves the reliability and accuracy of production plans. Qualified machines can complete production tasks on time and in the required quantities, preventing equipment failures or unstable operation from affecting the execution of the overall production plan.

[0034] It should be noted that by acquiring the dataset of machine operating status required for metal product processing and screening qualified machines, abnormal behavior or malfunctions of the machines can be detected in a timely manner. Screening and repairing abnormal machines helps reduce production downtime and improve production efficiency. By monitoring and analyzing machine operating status data, potential fault signs can be detected in advance, preventive maintenance can be carried out, maintenance costs can be reduced, the service life of equipment can be extended, qualified machines can be screened out for operation, ensuring stable equipment operation and effectively avoiding product quality problems caused by machine failures or abnormalities, thus ensuring that products meet quality standards.

[0035] Furthermore, the specific analysis process for evaluating the machine operating status required for metal product processing is as follows:

[0036]

[0037] In the formula, γ is the machine operating status evaluation value required for metal product processing, ZD is the machine operating vibration frequency required for metal product processing, T is the highest surface temperature required for metal product processing, RY is the lubricating oil pressure required for metal product processing, ZD0 is the reference vibration frequency required for metal product processing stored in the database, T0 is the highest reference surface temperature required for metal product processing stored in the database, RY0 is the reference lubricating oil pressure required for metal product processing stored in the database, θ1 is the compensation factor for the set vibration frequency required for metal product processing, θ2 is the compensation factor for the set highest surface temperature required for metal product processing, θ3 is the compensation factor for the set lubricating oil pressure required for metal product processing, and e is the natural constant.

[0038] It should be explained that the aforementioned machine operating status assessment values ​​for metal product processing are calculated based on the machine's vibration frequency, maximum surface temperature, and lubricating oil pressure during operation. Monitoring vibration frequency and maximum surface temperature helps predict potential machine malfunctions or problems, allowing for timely repair or component replacement to prevent downtime and production interruptions. It also enables timely adjustment of production parameters, optimization of the processing process, and improvement of production efficiency and product quality. Furthermore, it helps identify potential safety hazards, such as overheating or abnormal vibration, thus preventing potential accidents and personal injury. Additionally, it allows for timely adjustment of the lubrication system to ensure normal machine operation, extend equipment life, reduce maintenance and replacement costs, and ensure the quality of metal product processing, reducing defective products caused by machine condition issues. The maximum surface temperature and lubricating oil pressure are collected and recorded in real time by sensors or monitoring equipment. Sensors can be directly installed on key parts of the machine, such as bearings and motors, to monitor vibration frequency and temperature. Lubricating oil pressure can be obtained through pressure sensors in the lubrication system. These sensors send data to a data acquisition system or controller for processing and storage. The reference values ​​stored in the database are derived from historical data analysis and experiments, representing the standard values ​​of the machine under normal operating conditions. These data can be determined based on the machine model, technical specifications provided by the manufacturer, or experiential knowledge, and stored in the database or factory management system for reference and comparison. The compensation factors are adjusted and set according to specific production environments and machine operating conditions. These factors can be determined based on actual production needs and experiential knowledge to correct and adjust the reference values ​​to adapt to different process conditions and production requirements.

[0039] The metal product screening module for qualified appearance is used to acquire a dataset of the appearance status of qualified machine-processed metal products, and to screen metal products that meet the appearance status requirements based on the acquired dataset of the appearance status of qualified machine-processed metal products.

[0040] Specifically, the dataset of the appearance status of qualified machined metal products includes the number of cracks exceeding the defined length, the number of bubbles exceeding the defined area, and the maximum dent depth. The number of cracks exceeding the defined length refers to the number of cracks on the manufactured metal product that exceed the specified length during the machining process. Cracks may be caused by defects in the metal material, stress concentration during processing, improper process parameter settings, etc. The presence of cracks reduces the strength and durability of the metal product; therefore, exceeding the specified number of cracks may lead to product defects. The dataset also includes the number of bubbles exceeding the defined area. The number of bubbles refers to the number of bubbles exceeding a specified area on the surface of a manufactured metal product during machining. Bubbles are usually caused by gas inside or on the surface of the metal material that is not completely expelled during processing, resulting in bubbles being trapped inside or on the surface of the metal product. Too many bubbles will affect the appearance and surface quality of the metal product and may lead to insufficient strength or other quality problems. The maximum dent depth of a qualified machined metal product refers to the deepest dent or the maximum depth of a dent on the surface of the metal product. Dents may be caused by mechanical cutting or other processes during processing. The presence of dents may affect the appearance, surface quality, and functionality of the metal product. Therefore, its depth needs to be monitored and controlled to ensure that it is within the specified range.

[0041] It should be noted that the cracks and bubbles mentioned above are caused by defects inside or on the surface of the metal during the manufacturing process. If there are defects in the chemical composition or process parameters of the metal material, it may cause the formation of both cracks and bubbles at the same time. In the quality control process, it may be necessary to consider both indicators in order to find potential causes and solutions. The presence of cracks usually exacerbates the weakness and fragility of metal products, which may lead to more dents or deeper dents. If cracks exist during the manufacturing process, they may increase the risk of dents or deepen the depth of existing dents. The presence of bubbles may affect the surface flatness and structural stability of metal products, thereby increasing the risk of dents or deepening the depth of existing dents. If bubbles accumulate in a certain area, it may make the surface of that area more prone to dents.

[0042] Furthermore, based on the acquired dataset of the appearance status of qualified machine-processed metal products, metal products with acceptable appearance status are screened. The specific analysis process is as follows: Based on the acquired dataset of the appearance status of qualified machine-processed metal products, a comprehensive analysis is conducted to obtain the appearance status evaluation value of the qualified machine-processed metal products. The appearance status evaluation value of the qualified machine-processed metal products is used as the basis for screening the qualified appearance status of metal products. The appearance status evaluation value of the qualified machine-processed metal products is compared with the reference evaluation value of the appearance status of qualified machine-processed metal products stored in the database. If the appearance status evaluation value of the qualified machine-processed metal products is higher than or equal to the reference evaluation value of the appearance status of the qualified machine-processed metal products, the metal product corresponding to the appearance status evaluation value is marked as a qualified appearance status metal product. If the appearance status evaluation value of the qualified machine-processed metal products is lower than the reference evaluation value of the appearance status of the qualified machine-processed metal products, the metal product corresponding to the appearance status evaluation value is marked as an unqualified appearance status metal product.

[0043] It should be noted that the above-mentioned process can be automated by using computer programs or automation tools, which greatly improves screening efficiency. Compared with manually inspecting each metal product, this automated method can quickly and accurately assess and mark the appearance condition. Based on a unified assessment standard, the results are consistent and reliable, reducing the impact of human factors and ensuring that the assessment of appearance condition remains consistent under different circumstances. Comparing the appearance condition assessment value with the reference assessment value helps to make more objective decisions. This data-driven approach can help manufacturers or quality inspection departments better understand which products meet the standards and which need further processing or rejection. Automated assessment methods can greatly reduce labor costs, eliminating the need for a large number of human resources for appearance inspection, thereby saving time and labor costs.

[0044] It should be noted that the above-mentioned screening of metal products that meet the appearance standards ensures that only products that meet the appearance standards are released to the market. This helps improve product quality, enhance corporate image, and strengthen product competitiveness. It can reduce defect rates and rework rates, lower product-related quality risks, and save corporate costs. Metal products that meet the appearance standards represent the company's emphasis on and strict control over product quality, which helps to enhance brand value and reputation, and increase consumers' trust and loyalty to the brand.

[0045] Specifically, the evaluation value of the appearance condition of qualified machine-processed metal products is analyzed as follows:

[0046]

[0047] In the formula, δ is the appearance condition evaluation value of a qualified machined metal product, LF is the number of cracks exceeding the defined length of a qualified machined metal product, QP is the number of bubbles exceeding the defined area of ​​a qualified machined metal product, OX is the maximum dent depth of a qualified machined metal product, LF0 is the number of permissible cracks exceeding the defined length of a qualified machined metal product stored in the database, QP0 is the number of permissible bubbles exceeding the defined area of ​​a qualified machined metal product stored in the database, OX0 is the permissible dent depth of a qualified machined metal product stored in the database, μ1 is the compensation factor for the number of cracks exceeding the defined length of a qualified machined metal product, μ2 is the compensation factor for the number of bubbles exceeding the defined area of ​​a qualified machined metal product, and μ3 is the compensation factor for the maximum dent depth of a qualified machined metal product.

[0048] It should be explained that the aforementioned evaluation values ​​for the appearance of machined metal products are calculated based on the number of cracks exceeding the defined length, the number of bubbles exceeding the defined area, and the maximum dent depth of machined metal products. This allows for the timely detection and identification of potential quality problems during production. This helps manufacturers take timely measures to ensure products meet specified quality standards, reduce the production of defective products, and quantitatively assess the quantity and severity of defects such as cracks, bubbles, and dents. It also allows for the analysis of potential problems and defects during production, thereby optimizing production processes and machining parameters. This helps improve production efficiency, reduce production costs, and ultimately improve product quality. Timely detection and resolution of product quality issues ensures the delivery of high-quality products that meet customer expectations. This helps improve customer satisfaction and enhance customer trust and loyalty. The number of cracks exceeding the defined length, the number of bubbles exceeding the defined area, and the maximum dent depth in qualified machined metal products are usually obtained through quality inspection and testing of metal products produced during the production process. This data may be collected by the quality inspection department or automated systems. The number of permissible cracks exceeding the defined length, the number of permissible bubbles exceeding the defined area, and the permissible dent depth in qualified machined metal products stored in the database are set according to product specifications, industry standards, or customer requirements. The compensation factor is set by the manufacturer, quality inspection department, or technical experts based on production practice and experience. Its purpose is to take into account certain specific factors, such as material characteristics, processing technology, and environmental conditions, when evaluating product quality, so as to more accurately reflect the actual quality status of the product.

[0049] The qualified metal products screening module is used to preheat metal products that meet the appearance requirements, acquire infrared thermal imaging status datasets of the qualified metal products, and screen qualified metal products based on the acquired infrared thermal imaging status datasets.

[0050] Specifically, the infrared thermal imaging data set of metal products with acceptable appearance includes the maximum surface temperature difference, the number of temperature anomaly areas, and the temperature change rate. The maximum surface temperature difference refers to the temperature range of the metal product surface over a period of time, specifically the difference between the highest and lowest temperatures measured within a specific timeframe. This value can be used to assess the degree of temperature fluctuation on the metal product surface; generally, the smaller the temperature fluctuation, the higher the product's quality stability. The number of temperature anomaly areas refers to the number of temperature anomalies or abnormal temperature regions appearing on the surface of the metal product. These anomalies may be caused by production process failures, material defects, or other reasons. The number of abnormal temperature regions can be used to assess the quality of the metal product; the fewer abnormal temperature regions, the higher the product quality. The temperature change rate is the rate at which the surface temperature of the metal product changes over time. It represents the temperature changes of the metal product during production or transportation. Rapid temperature changes may lead to deformation or other quality problems in the metal product; therefore, the temperature change rate can be used as one of the indicators for assessing the acceptable appearance of metal products. The more stable the temperature change rate, the higher the product quality.

[0051] It should be noted that if the surface temperature of the metal product changes significantly, it may increase the number of temperature anomaly areas. A large temperature difference means that there may be a greater temperature difference on the metal surface at the same time, which may cause the temperature in a local area to exceed the normal range and cause anomalies. If the temperature change rate of the metal product is very high, it may increase the number of temperature anomaly areas. Rapid temperature changes may cause thermal stress on the metal surface, thereby increasing the possibility of anomalies. The higher the temperature change rate, the greater the surface temperature difference may be. Rapid temperature changes will cause the metal surface temperature to change rapidly in a short period of time, thereby increasing the maximum surface temperature difference.

[0052] Furthermore, based on the acquired infrared thermal imaging status dataset of metal products with acceptable appearance, qualified metal products are screened. The specific analysis process is as follows: Based on the acquired infrared thermal imaging status dataset of metal products with acceptable appearance, a comprehensive analysis is conducted to obtain the infrared thermal imaging status evaluation value of the metal products with acceptable appearance. The infrared thermal imaging status evaluation value of the metal products with acceptable appearance is used as the basis for screening qualified metal products. The infrared thermal imaging status evaluation value of the metal products with acceptable appearance is compared with the infrared thermal imaging status reference evaluation value of the metal products with acceptable appearance stored in the database. If the infrared thermal imaging status evaluation value of the metal products with acceptable appearance is higher than or equal to the infrared thermal imaging status reference evaluation value of the metal products with acceptable appearance, then the metal products with acceptable appearance corresponding to the infrared thermal imaging status evaluation value are marked as qualified metal products. If the infrared thermal imaging status evaluation value of the metal products with acceptable appearance is lower than the infrared thermal imaging status reference evaluation value of the metal products with acceptable appearance, then the metal products with acceptable appearance corresponding to the infrared thermal imaging status evaluation value of the metal products with acceptable appearance are marked as unqualified metal products.

[0053] It should be noted that the aforementioned use of infrared thermal imaging technology can acquire surface temperature distribution information of metal products without direct contact with each product, thereby improving screening efficiency. Infrared thermal imaging technology can provide a comprehensive assessment of the surface temperature of metal products, not just limited to specific points or areas. This method can objectively assess the appearance of metal products, reducing the possibility of subjective judgment. By comparing the real-time acquired infrared thermal imaging status assessment values ​​with reference assessment values ​​stored in the database, abnormalities in metal products can be detected in a timely manner, and appropriate marking and processing can be carried out, thereby improving the efficiency and accuracy of quality control. Timely screening of unqualified metal products can prevent them from entering downstream production stages or flowing into the market, thereby reducing the production cost of defective products and the potential quality problems they may cause, and improving the overall production quality. As an advanced non-destructive testing method, infrared thermal imaging technology has high sustainability and applicability, can be continuously applied in the production process, and its screening efficiency and accuracy can be continuously optimized and improved with technological advancements.

[0054] It should be noted that the above-mentioned preheating treatment of metal products with acceptable appearance and screening of qualified metal products can homogenize the internal temperature of the metal products, reducing errors in thermal imaging results caused by uneven temperature. In this way, infrared thermal imaging can more accurately detect defects or abnormalities in metal products. Preheating treatment ensures that the metal products reach the required temperature before entering the thermal imaging equipment, reducing waiting time during the thermal imaging process, thereby improving the efficiency and throughput of the production line. Through preheating treatment, the energy required during the thermal imaging process can be reduced, because the metal products are preheated to a certain temperature, reducing the energy consumption of the thermal imaging equipment. By more accurately detecting defects or abnormalities in metal products, timely measures can be taken to repair or reject unqualified products, thereby reducing the scrap rate and production costs.

[0055] Specifically, the infrared thermal imaging status assessment values ​​for metal products with acceptable appearance are analyzed as follows:

[0056]

[0057] In the formula, ω is the infrared thermal imaging status evaluation value of the metal product with qualified appearance, WC is the maximum difference in surface temperature of the metal product with qualified appearance, WY is the number of temperature abnormal areas of the metal product with qualified appearance, WB is the temperature change rate of the metal product with qualified appearance, WC0 is the surface temperature boundary difference of the metal product with qualified appearance stored in the database, WY0 is the number of temperature abnormal boundary areas of the metal product with qualified appearance stored in the database, WB0 is the reference temperature change rate of the metal product with qualified appearance stored in the database, σ1 is the compensation factor for the maximum difference in surface temperature of the metal product with qualified appearance, σ2 is the compensation factor for the number of temperature abnormal areas of the metal product with qualified appearance, σ3 is the compensation factor for the temperature change rate of the metal product with qualified appearance, and e is a natural constant.

[0058] It should be explained that the infrared thermal imaging condition assessment values ​​for metal products with acceptable appearance are calculated based on the maximum surface temperature difference, the number of temperature anomaly areas, and the rate of temperature change. Infrared thermal imaging technology can provide more comprehensive quality control and inspection, assessing surface temperature differences, the number of anomaly areas, and the rate of temperature change. This allows for more accurate detection of potential defects, problems, or non-conforming areas. Detecting temperature anomalies and their rates of change helps identify surface problems or abnormalities in metal products early, facilitating timely corrective measures, preventing further deterioration, and reducing the production of defective products. Using infrared thermal imaging for condition assessment enables non-contact, rapid, and efficient inspection, improving production line efficiency and reducing human and time costs. Analyzing surface temperature differences and trends provides insights into the production process. This process identifies problems and potential areas for improvement, guiding the optimization of production processes and the improvement of quality management. This enhances product quality and consistency. Timely detection and resolution of problems during production can reduce defective products and scrap rates, thereby saving production costs and resource input. High-precision temperature sensors are used to directly measure the surface temperature of metal products, obtaining the maximum temperature difference of metal products with acceptable appearance, the number of temperature anomaly areas, and the rate of temperature change for metal products with acceptable appearance. Parameters such as the temperature boundary difference, the number of temperature anomaly boundary areas, and the rate of temperature change for metal products with acceptable appearance stored in the database are typically derived through historical data analysis and statistics. The setting of compensation factors may rely on expert experience and judgment. Compensation factors are used to adjust or correct the results obtained from direct measurement or data analysis to more accurately reflect the actual state of the metal products.

[0059] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

Claims

1. A detection system based on metal product processing, characterized in that, This includes a qualified machine screening module, a qualified metal product screening module, and a qualified metal product screening module, among which: The qualified machine screening module acquires a dataset of machine operating status required for metal product processing, and screens qualified machines based on the acquired dataset of machine operating status required for metal product processing. The metal product screening module with qualified appearance condition obtains a dataset of the appearance condition of qualified machine-processed metal products, and screens the metal products with qualified appearance condition based on the obtained dataset of the appearance condition of qualified machine-processed metal products. The qualified metal products screening module preheats qualified metal products, acquires an infrared thermal imaging status dataset of qualified metal products, and screens qualified metal products based on the acquired infrared thermal imaging status dataset.

2. The detection system based on metal product processing according to claim 1, characterized in that: The dataset of machine operating status required for metal product processing specifically includes the vibration frequency of the machine, the highest surface temperature of the machine, and the lubricating oil pressure during the operation of the machine.

3. The detection system based on metal product processing according to claim 2, characterized in that: Based on the acquired dataset of machine operating status required for metal product processing, qualified machines are screened. The specific analysis process is as follows: Based on the acquired dataset of machine operating status required for metal product processing, a comprehensive analysis is conducted to obtain the machine operating status evaluation value required for metal product processing. This evaluation value serves as the basis for screening qualified machines. The machine operating status assessment values ​​required for metal product processing are compared with the reference assessment values ​​for machine operating status required for metal product processing stored in the database. If the machine operation status assessment value required for metal product processing is higher than or equal to the reference assessment value required for metal product processing, then the machine operation status required for metal product processing corresponding to the assessment value is qualified, and the machine required for metal product processing is marked as a qualified machine. If the machine operating status assessment value required for metal product processing is lower than the reference assessment value required for metal product processing, then the machine operating status required for metal product processing corresponding to the assessment value is unqualified. The machine required for metal product processing will be marked as unqualified and an unqualified alarm will be issued for the unqualified machine.

4. The detection system based on metal product processing according to claim 3, characterized in that: The specific analysis process for the machine operating status assessment values ​​required for metal product processing is as follows: In the formula, γ is the machine operating status evaluation value required for metal product processing, ZD is the machine operating vibration frequency required for metal product processing, T is the highest surface temperature required for metal product processing, RY is the lubricating oil pressure required for metal product processing, ZD0 is the reference vibration frequency required for metal product processing stored in the database, T0 is the highest reference surface temperature required for metal product processing stored in the database, RY0 is the reference lubricating oil pressure required for metal product processing stored in the database, θ1 is the compensation factor for the set vibration frequency required for metal product processing, θ2 is the compensation factor for the set highest surface temperature required for metal product processing, θ3 is the compensation factor for the set lubricating oil pressure required for metal product processing, and e is the natural constant.

5. The detection system based on metal product processing according to claim 1, characterized in that: The dataset of the appearance status of qualified machine-processed metal products specifically includes the number of cracks exceeding the defined length, the number of bubbles exceeding the defined area, and the maximum dent depth of the qualified machine-processed metal products.

6. The detection system based on metal product processing according to claim 5, characterized in that: The process of filtering out metal products with acceptable appearance based on the acquired dataset of qualified machine-processed metal products is as follows: Based on the obtained dataset of the appearance status of qualified machine-processed metal products, a comprehensive analysis is conducted to obtain the appearance status evaluation value of qualified machine-processed metal products. The appearance status evaluation value of qualified machine-processed metal products serves as the basis for screening qualified metal products. The appearance condition assessment value of qualified machine-processed metal products is compared with the reference assessment value of qualified machine-processed metal products stored in the database. If the appearance condition assessment value of a metal product processed by a qualified machine is higher than or equal to the reference assessment value of the appearance condition of a metal product processed by a qualified machine, then the metal product corresponding to the appearance condition assessment value of the metal product processed by the qualified machine is marked as a metal product with qualified appearance condition. If the appearance condition assessment value of a metal product processed by a qualified machine is lower than the reference assessment value of the appearance condition of a metal product processed by a qualified machine, then the metal product corresponding to the appearance condition assessment value of the qualified machine-processed metal product is marked as a metal product with an unqualified appearance condition.

7. The detection system based on metal product processing according to claim 6, characterized in that: The specific analysis process for evaluating the appearance of metal products processed by qualified machines is as follows: In the formula, δ is the appearance condition evaluation value of a qualified machined metal product, LF is the number of cracks exceeding the defined length of a qualified machined metal product, QP is the number of bubbles exceeding the defined area of ​​a qualified machined metal product, OX is the maximum dent depth of a qualified machined metal product, LF0 is the number of permissible cracks exceeding the defined length of a qualified machined metal product stored in the database, QP0 is the number of permissible bubbles exceeding the defined area of ​​a qualified machined metal product stored in the database, OX0 is the permissible dent depth of a qualified machined metal product stored in the database, μ1 is the compensation factor for the number of cracks exceeding the defined length of a qualified machined metal product, μ2 is the compensation factor for the number of bubbles exceeding the defined area of ​​a qualified machined metal product, and μ3 is the compensation factor for the maximum dent depth of a qualified machined metal product.

8. The detection system based on metal product processing according to claim 1, characterized in that: The infrared thermal imaging status dataset of metal products with acceptable appearance includes the maximum temperature difference on the surface of the metal products with acceptable appearance, the number of temperature anomaly areas in the metal products with acceptable appearance, and the rate of temperature change of the metal products with acceptable appearance.

9. The detection system based on metal product processing according to claim 8, characterized in that: The process of screening qualified metal products based on the acquired infrared thermal imaging data set of qualified metal products is as follows: Based on the acquired infrared thermal imaging status dataset of metal products with qualified appearance, a comprehensive analysis is conducted to obtain the infrared thermal imaging status evaluation value of the metal products with qualified appearance. The infrared thermal imaging status evaluation value of the metal products with qualified appearance serves as the basis for the analysis of screening qualified metal products. The infrared thermal imaging status evaluation value of the metal products with acceptable appearance is compared with the infrared thermal imaging status reference evaluation value of the metal products with acceptable appearance stored in the database. If the infrared thermal imaging status evaluation value of a metal product with acceptable appearance is higher than or equal to the infrared thermal imaging status reference evaluation value of a metal product with acceptable appearance, then the metal product with acceptable appearance corresponding to the infrared thermal imaging status evaluation value of the metal product with acceptable appearance is marked as a qualified metal product. If the infrared thermal imaging status assessment value of a metal product with acceptable appearance is lower than the reference assessment value of the infrared thermal imaging status of a metal product with acceptable appearance, then the metal product with acceptable appearance corresponding to the infrared thermal imaging status assessment value of the metal product with acceptable appearance will be marked as an unacceptable metal product.

10. The detection system based on metal product processing according to claim 9, characterized in that: The specific analysis process for the infrared thermal imaging status evaluation value of the metal product with acceptable appearance is as follows: In the formula, ω is the infrared thermal imaging status evaluation value of the metal product with qualified appearance, WC is the maximum difference in surface temperature of the metal product with qualified appearance, WY is the number of temperature abnormal areas of the metal product with qualified appearance, WB is the temperature change rate of the metal product with qualified appearance, WC0 is the surface temperature boundary difference of the metal product with qualified appearance stored in the database, WY0 is the number of temperature abnormal boundary areas of the metal product with qualified appearance stored in the database, WB0 is the reference temperature change rate of the metal product with qualified appearance stored in the database, σ1 is the compensation factor for the maximum difference in surface temperature of the metal product with qualified appearance, σ2 is the compensation factor for the number of temperature abnormal areas of the metal product with qualified appearance, σ3 is the compensation factor for the temperature change rate of the metal product with qualified appearance, and e is a natural constant.

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