Bullet train wheel pair surface defect fluorescent magnetic powder nondestructive detection equipment and detection method

Abstract

The invention discloses a bullet train wheel pair surface defect fluorescent magnetic powder nondestructive testing device and method, and belongs to the technical field of nondestructive testing equipment, the bullet train wheel pair surface defect fluorescent magnetic powder nondestructive testing device comprises a truss manipulator device, a composite magnetization mechanism, a wheel pair lifting and rotating mechanism, a chain conveying device, a rotating detection mechanism, a steering lamp mechanism, a spraying device, a portal frame, a liquid collecting box and a base station; the truss manipulator device comprises a longitudinal moving mechanism, a transverse moving mechanism and a grabbing mechanism and is used for feeding wheel sets; the chain conveying device is fixed in the middle of the base station and used for conveying the wheel set to a detection position; the composite magnetization mechanisms are arranged at the two ends of the base table and used for conducting axial and circumferential magnetization on the wheel set. The portal frame is arranged above the base station, and the rotary detection mechanism, the steering lamp mechanism and the spraying device are all mounted on the portal frame; a liquid collecting box is arranged on the lower side of the chain conveying device, and the wheel pair lifting and rotating mechanism is installed in the middle of the inner side of the liquid collecting box and can lift the wheel pair and drive the wheel pair to rotate.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of nondestructive testing equipment, and particularly relates to a high-speed train wheel set surface defect fluorescent magnetic powder nondestructive testing equipment. BACKGROUND

[0002] Fluorescent magnetic powder testing is a nondestructive testing method widely applied to the surface and near-surface defects of ferromagnetic materials. The basic principle is that an external magnetic field is applied to the workpiece to magnetize it, and when there is a crack defect at the surface or near the surface of the workpiece at a certain angle with the magnetic field direction, the magnetic force line will be distorted in the defect area and form a leakage magnetic field. At this time, if a fluorescent magnetic suspension liquid with certain viscosity and magnetic conductivity is sprayed on the surface of the workpiece, the leakage magnetic field at the defect will adsorb the magnetic powder, which will gather to form a magnetic mark visible under ultraviolet light, thereby realizing the identification and positioning of the defect.

[0003] The wheel set of the high-speed train is the part contacting with the steel rail on the high-speed train vehicle, which is composed of a wheel and an axle, and further includes a driving part and a braking part. The wheel set functions to ensure the running and steering of the high-speed train vehicle on the steel rail, bears the entire static load and dynamic load from the high-speed train vehicle, transmits the load to the steel rail, and transmits the load generated due to the irregularity of the line to each component of the high-speed train vehicle.

[0004] The wheel set is a key component for the running of the high-speed train, and directly relates to the safety of the high-speed train vehicle during running. Therefore, it is necessary to perform fluorescent magnetic powder testing on the wheel set during manufacturing and maintenance of the high-speed train to detect the surface and near-surface defects of the wheel set and eliminate the risks.

[0005] The existing high-speed train wheel set flaw detection is usually performed in a semi-automatic manner by using a fluorescent magnetic powder flaw detector and manual observation. During the detection process, manual operations such as loading, spraying of the magnetic suspension liquid, and observation of the magnetic mark are required, which consumes a long time and has low detection efficiency. In addition, the manual observation of the magnetic mark is easily affected by factors such as visual fatigue and subjective judgment, resulting in a large number of missed detection and false detection of the wheel set cracks. SUMMARY

[0006] The present application aims to solve the problems of low efficiency, easy missed detection and false detection caused by the dependence on manual operation in the existing fluorescent magnetic powder detection of the high-speed train wheel set, and provides a high-speed train wheel set surface defect fluorescent magnetic powder nondestructive testing equipment and a detection method.

[0007] A high-speed train wheel set surface defect fluorescent magnetic powder nondestructive testing equipment comprises a truss mechanical hand device, a composite magnetizing mechanism, a wheel set lifting and rotating mechanism, a chain conveying device, a rotating detection mechanism, a steering lamp mechanism, a spraying device, a gantry, a liquid collecting tank, and a base.

[0008] The truss manipulator is located on one side of the device and includes a longitudinal movement mechanism, a lateral movement mechanism, and a gripping mechanism.

[0009] The chain conveyor is fixed in the middle of the base, and the composite magnetization mechanism is located at both ends of the base.

[0010] The gantry frame is mounted on the base, and the rotation detection mechanism, the turn signal mechanism, and the spraying device are all installed on the gantry frame.

[0011] The chain conveyor is provided with a liquid collection tank on its lower side, and the wheel pair lifting and rotating mechanism is installed in the middle of the inner side of the liquid collection tank.

[0012] The composite magnetization mechanism includes a support body, a back plate, a cylinder, a C-shaped connecting block, electrode plates, an electromagnet core, a coil cylinder, and an electromagnetic coil.

[0013] The support is mounted on the base platform. It has a hollow structure and a back plate on the outside. The inner side of the back plate is fixedly connected to the cylinder.

[0014] The outer side of the coil drum is provided with a C-shaped connecting block, which slides against the inner wall of the support body.

[0015] The coil tube is connected inward to the piston rod of the cylinder;

[0016] An electromagnetic coil is wound on the coil drum, the electromagnet core is fixed on the inner surface of the coil drum, and the electrode plate is fixed on the front end of the electromagnet core.

[0017] When the wheelset is magnetized, the cylinder piston rod extends and presses against both ends of the wheelset shaft, and the electromagnetic coil is energized to complete the axial magnetization of the wheelset; when the electromagnetic coil is de-energized, the electrode plates are energized to complete the circumferential magnetization of the wheelset.

[0018] The rotating detection mechanism is installed in the gantry and on a drivable rectangular connecting block, and includes: a camera mounting bracket, a camera, a fourth motor, a fifth motor, and a vertical plate;

[0019] The fifth motor is fixed to the lower end of the rectangular connecting block, and its output shaft is fixedly connected to the camera mounting bracket.

[0020] The two ends of the camera are connected to the camera mounting bracket, and its rotating shaft is perpendicular to the output shaft of the fifth motor.

[0021] The camera is driven to rotate by a fourth motor on one side of the camera mount;

[0022] The fifth motor drives the camera mount to rotate around the vertical axis from -90° to 90°, and the fourth motor drives the camera to rotate around the horizontal axis from -90° to 90°.

[0023] The turn signal mechanism includes a third motor, a lamp mounting plate, and a lamp;

[0024] The third motor is fixed to the upper end of the gantry frame;

[0025] The two ends of the lamp fixing plate are axially connected to the middle of the gantry frame, and strip lamps are installed on it;

[0026] The third motor drives the lamp mounting plate to rotate from -90° to 90°.

[0027] The chain conveying device includes a support base, sprocket, positioning block, drive shaft, reduction motor, chain, and support plate;

[0028] The support bases are rectangularly distributed with a pair on each of the left and right sides and fixed to the ground. Each pair of support bases is axially connected to a drive shaft.

[0029] Both the inner and outer ends of the drive shaft are fixedly connected to sprockets, and the inner and outer sprockets are respectively connected by chains on both sides.

[0030] Each link of the sprocket is fixed with a positioning block, and two pairs of support plates are provided on the inner and outer sides.

[0031] The upper edge of the support plate slides into the chain at the corresponding position;

[0032] One of the two drive shafts is connected to the output shaft of the geared motor.

[0033] The truss manipulator places the wheelset on the chain, and the wheel rim of the wheelset is positioned by engaging with the positioning block. The geared motor is powered on to drive the chain to move.

[0034] When the wheelset is transferred to the detection position, the geared motor is de-energized, the chain stops moving, the wheelset lifting and rotating mechanism rises until the wheelset is disengaged from the chain, and drives the wheelset to rotate. Then, the wheelset is sprayed with fluorescent magnetic suspension, magnetized, and image acquired and detected in sequence.

[0035] The gantry includes a fourth guide rail, a fourth slider, a stop block, a rectangular connecting block, a sixth motor, a fifth slider, a moving crossbeam, a seventh motor, and a fifth guide rail.

[0036] The gantry frame is provided with vertical fourth guide rails on both sides, and a fourth slider is slidably connected on the fourth guide rails, with a stop block at the upper end;

[0037] The fourth sliders on both sides are fixedly connected to both ends of the moving crossbeam.

[0038] The movable crossbeam is perpendicular to the fourth guide rail, and a seventh motor is installed at both ends of the crossbeam. The seventh motor synchronously drives the movable crossbeam to move up and down.

[0039] A fifth guide rail is installed parallel to the moving crossbeam, and the fifth slider slides on the fifth guide rail;

[0040] The rectangular connecting block is sleeved on the moving crossbeam, and its inner upper end is fixedly connected to the upper end of the fifth slider.

[0041] A sixth motor is installed on one side of the rectangular connecting block, which enables the rectangular connecting block to move along the long side of the moving crossbeam.

[0042] The longitudinal movement mechanism of the truss manipulator includes a column, a first slider, a first guide rail, a first hydraulic cylinder, and a first crossbeam;

[0043] The column has a pair of guide rails fixed to the ground on both its inner and outer sides.

[0044] The first slider slides on the first guide rail, and the first slider on the same side is fixedly connected to both ends of the first crossbeam.

[0045] The first crossbeam is perpendicular to the first guide rail. A first hydraulic cylinder is provided below the first crossbeam on both sides. The first hydraulic cylinders on both sides are driven synchronously to make the first crossbeams on both sides move up and down longitudinally in sync; thus completing the lifting operation when loading wheelsets.

[0046] The lateral movement mechanism of the truss manipulator includes a second guide rail, a second motor, a second slider, a first rack, a second gear, and a second crossbeam;

[0047] The first crossbeams on both sides are horizontally fixed with second guide rails, and the two ends of the second crossbeams are fixed with second sliders. The second sliders slide with the second guide rails on both sides respectively, and the second crossbeams are set perpendicular to the second guide rails.

[0048] A second motor is installed at both ends of the second crossbeam, and a second gear is installed on the output shaft of each of the second motors;

[0049] The first crossbeam is fixed to the outer side of the first transverse rack. The second gear meshes with the first rack. The second motors on both sides synchronously drive the second crossbeam to move laterally left and right, completing the lateral movement operation when loading the wheelset.

[0050] The gripping mechanism of the truss manipulator includes a second hydraulic cylinder, a third slider, a third guide rail, and a second fixed block lifting ring;

[0051] Two third guide rails are fixed to both ends of the second crossbeam, and a third slider slides on the third guide rails;

[0052] The third slider is provided with a lifting ring on its lower side, and the lifting ring is provided with a hollow U-shaped groove and a buffer pad is pasted on the inner side;

[0053] The second hydraulic cylinder is installed at both ends of the second crossbeam, driving the two lifting rings on both sides to move towards each other and away from each other; thus completing the gripping and placement of the wheelset.

[0054] Another objective of this invention is to provide a method for non-destructive testing of surface defects in high-speed train wheelsets using fluorescent magnetic powder.

[0055] A method for non-destructive testing of surface defects in power train wheelsets using fluorescent magnetic particle testing equipment, comprising the following steps:

[0056] S1. Loading of wheelsets:

[0057] The piston rod of the second hydraulic cylinder of the gripping mechanism extends, driving the lifting rings to move towards each other to the clamping position;

[0058] The piston rods of the four first hydraulic cylinders extend synchronously, driving the entire gripping mechanism and wheelset to rise vertically to the set position via the first crossbeam;

[0059] Two second motors start synchronously, and through the meshing transmission of the second gear and the first rack, drive the second crossbeam and the wheelset it grips to move laterally to above the starting section of the chain conveyor.

[0060] The first hydraulic cylinder retracts, precisely placing the wheelset between the positioning blocks of the chain, and then the lifting ring is released and reset.

[0061] The geared motor of the chain conveyor then starts, driving the chain through the chain drive system to transport the wheelset to the inspection station;

[0062] When the reduction motor stops, the wheelset lifting and rotating mechanism rises, lifting the wheelset away from the positioning block of the chain, and driving the wheelset to rotate at a constant speed.

[0063] S2. Spray and magnetize the fluorescent magnetic suspension:

[0064] As the wheelset rotates, the spraying device evenly sprays fluorescent magnetic suspension liquid onto its surface;

[0065] The composite magnetization mechanism begins to work: its cylinder piston rod extends, pushing the entire magnetization assembly forward, so that the electrode plate makes close contact with the wheel set shaft end;

[0066] When the electromagnetic coil is energized, the wheelset is axially magnetized; after magnetization is completed, the electromagnetic coil is de-energized and the electrode plates are energized to circumferentially magnetize the wheelset.

[0067] S3. Image acquisition and detection after magnetization:

[0068] After each magnetization is completed, the turn signal mechanism and the rotation detection mechanism start to work: the third motor of the turn signal mechanism drives the lamp mounting plate and the lamp to rotate to the optimal supplementary lighting angle through the gear pair;

[0069] Meanwhile, the seventh motor on the gantry frame drives the moving crossbeam to descend to a predetermined height via a gear and rack pair, while the sixth motor drives the rectangular connecting block and its rotating detection mechanism to move along the wheel pair axis.

[0070] During this period, the fifth motor drives the camera mount to swing around the vertical axis, and the fourth motor drives the camera to pitch around the horizontal axis, thereby achieving 360° image acquisition of the wheel set surface without blind spots;

[0071] S4. Circular feeding and inspection of wheelsets:

[0072] While the first wheel is acquiring images, the gantry robot simultaneously loads the second wheel pair, forming a continuous operation. After the first wheel pair is inspected, all actuators are reset, the chain conveyor sends it out, and at the same time, the second wheel pair is sent into the inspection station. This cycle is repeated to achieve continuous automated inspection.

[0073] This invention provides a fluorescent magnetic particle nondestructive testing device and method for surface defects of power train wheelsets, belonging to the technical field of nondestructive testing equipment. It includes: a gantry manipulator, a composite magnetization mechanism, a wheelset lifting and rotating mechanism, a chain conveyor, a rotating inspection mechanism, a turn signal mechanism, a spraying device, a gantry frame, a collection tank, and a base. The gantry manipulator includes a longitudinal movement mechanism, a lateral movement mechanism, and a gripping mechanism for loading the wheelsets. The chain conveyor is fixed in the middle of the base and is used to deliver the wheelsets to the inspection position. The composite magnetization mechanism is located at both ends of the base and is used to magnetize the wheelsets axially and circumferentially. The gantry frame is located above the base, and the rotating inspection mechanism, turn signal mechanism, and spraying device are all mounted on the gantry frame. A collection tank is located below the chain conveyor, and the wheelset lifting and rotating mechanism is installed in the middle of the inner side of the collection tank, lifting the wheelsets and driving them to rotate.

[0074] The beneficial effects and advantages of this invention compared with the prior art are as follows:

[0075] 1. This invention achieves full automation of wheelset loading, conveying, and unloading through an automatic loading and unloading mechanism consisting of a gantry robot and a chain conveyor, significantly improving inspection efficiency.

[0076] 2. By using a multi-degree-of-freedom adjustable image acquisition system, combined with the rotational motion of the wheelset, high-definition image acquisition of complex contour surfaces without blind spots is achieved, fundamentally avoiding subjective errors in manual interpretation and greatly improving the accuracy and reliability of detection.

[0077] 3. By using a composite magnetization mechanism, axial and circumferential magnetization functions are integrated at the same workstation, which can effectively excite surface defects in different directions and ensure the comprehensiveness of the inspection.

[0078] 4. The various functional modules work together to form a highly integrated and automated testing system, which meets the high standards of testing quality and efficiency required by modern rail transit. Attached Figure Description

[0079] Figure 1 This is a three-dimensional structural schematic diagram of a fluorescent magnetic particle non-destructive testing device for surface defects of high-speed train wheelsets according to the present invention;

[0080] Figure 2 This is a front view of a fluorescent magnetic particle non-destructive testing device for surface defects of high-speed train wheelsets according to the present invention;

[0081] Figure 3 This is a top view of a fluorescent magnetic particle non-destructive testing device for surface defects of high-speed train wheelsets according to the present invention;

[0082] Figure 4 This is a left view of a fluorescent magnetic particle non-destructive testing device for surface defects of high-speed train wheelsets according to the present invention.

[0083] Figure 5 This is a schematic diagram of the overall structure of the gantry manipulator device in the fluorescent magnetic particle non-destructive testing equipment for surface defects of motor wheelsets according to the present invention;

[0084] Figure 6 This is a schematic diagram of the overall structure of the chain conveyor in the fluorescent magnetic particle non-destructive testing equipment for surface defects of motor wheelsets according to the present invention;

[0085] Figure 7 This is a schematic diagram of the overall structure of the gantry in the fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to the present invention;

[0086] Figure 8 This is a schematic diagram of the overall structure of the turn signal mechanism in the fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to the present invention;

[0087] Figure 9 This is a schematic diagram of the specific structure of the rotating detection mechanism in the fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to the present invention;

[0088] Figure 10 This is a schematic diagram of the composite magnetization mechanism in a fluorescent magnetic powder non-destructive testing device for surface defects of power train wheelsets according to the present invention.

[0089] In the attached diagram:

[0090] 1. Truss robot device; 101. Column; 102. First guide rail; 103. First hydraulic cylinder; 104. First slider; 105. Connecting sleeve; 106. Second guide rail; 107. First crossbeam; 108. Second motor; 109. Second motor support; 110. Second hydraulic cylinder support; 111. Second hydraulic cylinder; 112. Second fixing block; 113. Third slider; 114. Third guide rail; 115. Second crossbeam; 116. First rack; 117. Second gear; 118. Lifting ring; 119. Second slider;

[0091] 2. Composite magnetization mechanism; 201. Support body; 202. Back plate; 203. Cylinder; 204. Cross-shaped connecting plate; 205. Sixth guide rail; 206. Sixth slider; 207. C-shaped connecting block; 208. Electrode plate; 209. Electromagnetic core; 210. Coil tube; 211. Electromagnetic coil;

[0092] 3. Wheelset lifting and rotating mechanism;

[0093] 4. Chain conveyor; 401. Support base; 402. Sprocket; 403. Positioning block; 404. Drive shaft; 405. Gear motor; 406. Chain; 407. Support plate;

[0094] 5. Rotation detection mechanism; 501. Camera mount; 502. Camera; 503. Fourth motor; 504. Fifth motor; 505. Vertical plate;

[0095] 6. Turn signal mechanism; 601. Third motor; 602. Third motor support; 603. Third transmission pinion; 604. Third transmission gear; 605. Light fixture mounting plate; 606. Light fixture;

[0096] 7. Spraying device;

[0097] 8. Gantry frame; 801. Fourth guide rail; 802. Second rack; 803. Fourth slider; 804. Stop block; 805. Rectangular connecting block; 806. Sixth motor; 807. Fourth gear; 808. Fifth slider; 809. Moving crossbeam; 810. Seventh motor; 811. Third rack; 812. Fifth guide rail; 813. Third gear;

[0098] 9. Liquid collecting tank; 10. Abutment. Detailed Implementation

[0099] Example 1:

[0100] See appendix Figures 1-10A fluorescent magnetic particle non-destructive testing device for surface defects of motor vehicle wheelsets includes: a gantry manipulator device 1, a composite magnetization mechanism 2, a wheelset lifting and rotating mechanism 3, a chain conveying device 4, a rotating detection mechanism 5, a turn signal mechanism 6, a spraying device 7, a gantry frame 8, a liquid collection tank 9, and a base 10.

[0101] The gantry manipulator 1 adopts a portal structure and is located on one side of the device. It is used for gripping and loading wheelsets and includes a longitudinal movement mechanism, a lateral movement mechanism and a gripping mechanism.

[0102] The chain conveyor 4 is fixed in the middle of the base 10, and the composite magnetization mechanism 2 is located at both ends of the base 10.

[0103] The gantry frame 8 is located above the base 10, and the rotation detection mechanism 5, the turn signal mechanism 6 and the spray device 7 are installed on the upper end of the gantry frame 8.

[0104] The chain conveyor 4 has a liquid collection tank 9 on the lower side of the middle part, and the wheel set lifting and rotating mechanism 3 is installed in the middle position inside the liquid collection tank 9.

[0105] The composite magnetization mechanism 2 includes a support body 201, a back plate 202, a cylinder 203, a cross-shaped connecting plate 204, a sixth guide rail 205, a sixth slider 206, a C-shaped connecting block 207, an electrode sheet 208, an electromagnet core 209, a coil tube 210, and an electromagnetic coil 211.

[0106] The support 201 is fixedly connected to the base 10, and a back plate 202 is installed on its back. The inner side of the back plate 202 is fixedly connected to the bottom of the cylinder 203.

[0107] A C-shaped connecting block 207 is circumferentially mounted on the coil tube 210, and a sixth slider 206 is mounted on the outside of the C-shaped connecting block 207;

[0108] The inner wall of the support 201 is provided with a sixth guide rail 205, which is slidably connected to the sixth slider 206 in sequence.

[0109] The coil tube 210 is equipped with a cross-shaped connecting plate 204 on its back, which is connected to the piston rod of the cylinder 203;

[0110] An electromagnetic coil 211 is wound on the coil tube 210, an electromagnet core 209 is fixed on the inner surface of the coil tube 210, and an electrode plate 208 is fixed on the front end of the electromagnet core 209.

[0111] When the wheelset is magnetized, the piston rod of the cylinder 203 extends and presses against both ends of the wheelset shaft, and the electromagnetic coil 211 is energized to complete the axial magnetization of the wheelset; subsequently, the electromagnetic coil 211 is de-energized, and the electrode plate 208 is energized to complete the circumferential magnetization of the wheelset.

[0112] The rotating detection mechanism 5 is installed on the lower side of the rectangular connecting block 805 of the gantry 8, and includes: camera mounting bracket 501, camera 502, fourth motor 503, fifth motor 504, and upright plate 505;

[0113] The fifth motor 504 is fixed to the lower end of the inner side of the rectangular connecting block 805, and its output shaft passes through the lower side plate of the rectangular connecting block 805 and is fixedly connected to the camera mounting bracket 501.

[0114] The two ends of the camera 502 are axially connected to the camera mounting bracket 501, and its rotating shaft is perpendicular to the output shaft of the fifth motor 504.

[0115] The fourth motor 503 is mounted on one side of the camera mount 501 via an extended vertical plate 505, and the output shaft of the fourth motor 503 is connected to the rotating shaft of the camera 502.

[0116] The fifth motor 504 drives the camera mount 501 to rotate around the vertical axis from -90° to 90°, and the fourth motor 503 drives the camera 502 to rotate around the horizontal axis from -90° to 90°.

[0117] The turn signal mechanism 6 includes a third motor 601, a third motor support 602, a third transmission pinion 603, a third transmission gear 604, a lamp mounting plate 605, and a lamp 606.

[0118] The third motor 601 is fixed to the upper end of the gantry frame 8 by the third motor support 602, and the third transmission pinion 603 is installed on its output shaft.

[0119] One end of the lamp fixing plate 605 is connected to the gantry frame 8 shaft, and the other end is fixedly connected to the third transmission gear 604;

[0120] The other end of the third transmission large gear 604 is connected to the gantry frame 8 shaft, and it meshes with the third transmission small gear 603.

[0121] The lamp fixing plate 605 is rectangular, and a long strip lamp 606 is installed on it;

[0122] The third motor 601 drives the lamp fixing plate 605 to rotate from -90° to 90°.

[0123] The chain conveying device 4 includes a support base 401, a sprocket 402, a positioning block 403, a transmission shaft 404, a reduction motor 405, a chain 406, and a support plate 407.

[0124] The support bases 401 are rectangularly distributed with a pair on each of the left and right sides and are fixed to the ground. Each pair of support bases 401 is axially connected to a drive shaft 404.

[0125] Both ends of the left and right drive shafts 404 are fixed to sprockets 402, and the inner and outer sprockets 402 are respectively driven and connected by chains 406 on both sides.

[0126] Each link of the chain 406 is fixed with a positioning block 403, and two pairs of support plates 407 are provided on the inner and outer sides. The upper edge of the support plate 407 slides with the cage of the chain 406 at the corresponding position, that is, the support chain 406 forms a stable transmission section.

[0127] The middle part of one of the two drive shafts 404 is connected to the output shaft of the geared motor 405 via chain drive.

[0128] The truss manipulator 1 places the wheelset on the chain 406, and the wheel rim of the wheelset is positioned by fitting with the positioning block 403. The reduction motor 405 is energized to drive the chain 406 to move.

[0129] When the wheelset is transferred to the detection position, the geared motor 405 is de-energized, the chain 406 stops moving, and the wheelset lifting and rotating mechanism 3 rises until the wheelset is separated from the chain 406 by a certain distance and drives the wheelset to rotate.

[0130] The gantry frame 8 includes a fourth guide rail 801, a second rack 802, a fourth slider 803, a stop block 804, a rectangular connecting block 805, a sixth motor 806, a fourth gear 807, a fifth slider 808, a moving crossbeam 809, a seventh motor 810, a third rack 811, a fifth guide rail 812, and a third gear 813.

[0131] The gantry frame 8 is provided with vertical fourth guide rails 801 on both sides;

[0132] The fourth guide rail 801 is slidably connected to the fourth slider 803, and a stop block 804 is provided at the upper end;

[0133] The fourth sliders 803 on both sides are fixedly connected to both ends of the movable crossbeam 809, respectively.

[0134] The movable crossbeam 809 is perpendicular to the fourth guide rail 801, and a seventh motor 810 is installed at both ends of it.

[0135] The second rack 802 is provided parallel to the inner side of the fourth guide rail 801 on the gantry frame 8;

[0136] The third gear 813 is installed on the output shaft of the seventh motor 810, and the third gear 813 meshes with the second rack 802;

[0137] The seventh motors 810 on both sides synchronously drive the moving crossbeam 809 to move up and down;

[0138] A fifth guide rail 812 and a third rack 811 are mounted in parallel on the moving crossbeam 809;

[0139] The fifth slider 808 is slidably connected to the fifth guide rail 812;

[0140] The rectangular connecting block 805 is sleeved on the movable crossbeam 809, and its inner upper end is fixedly connected to the upper end of the fifth slider 808.

[0141] A sixth motor 806 is installed on one side of the rectangular connecting block 805. The output shaft of the sixth motor 806 is connected to a fourth gear 807. The fourth gear 807 meshes with the third rack 811, so that the rectangular connecting block 805 can move along the long side of the moving crossbeam 809.

[0142] The longitudinal movement mechanism of the truss manipulator 1 includes a column 101, a first slider 104, a first guide rail 102, a first hydraulic cylinder 103, a connecting sleeve 105, and a first crossbeam 107.

[0143] The columns 101 are arranged in a rectangular shape, with a pair on each of the inner and outer sides fixed to the ground, and the first guide rail 102 is vertically fixed on each of them;

[0144] The first slider 104 is slidably connected to the first guide rail 102, and the two pairs of first sliders 104 inside and outside are respectively fixed to the two ends of the first crossbeam 107 on the inner and outer sides through two pairs of connecting sleeves 105.

[0145] The first crossbeam 107 is perpendicular to the first guide rail 102. A first hydraulic cylinder 103 is provided below the first crossbeam 107 on both sides. The first hydraulic cylinders 103 on both sides are driven synchronously to make the first crossbeam 107 on both sides move up and down longitudinally synchronously; thus completing the lifting operation when loading wheelset.

[0146] The lateral movement mechanism of the truss manipulator 1 includes a second guide rail 106, a second motor 108, a second motor support 109, a second hydraulic cylinder support 110, a second slider 119, a first rack 116, a second gear 117, and a second crossbeam 115.

[0147] The first crossbeams 107 on both sides are horizontally fixed with second guide rails 106, and the two ends of the second crossbeams 115 are fixed with second sliders 119. The second sliders 119 slide with the second guide rails 106 on both sides respectively, and the second crossbeams 115 are perpendicular to the second guide rails 106.

[0148] The second crossbeam 115 is equipped with a second hydraulic cylinder support 110 at both ends, and a second motor support 109 is fixedly connected to the lower side of the second hydraulic cylinder support 110.

[0149] The second motor 108 is installed in the second motor support 109, and the second gear 117 is installed on the output shaft of the second motor 108.

[0150] The first crossbeam 107 is fixed to the outer side of the first transverse rack 116. The second gear 117 meshes with the first rack 116. That is, the second motors 108 on the inner and outer sides synchronously drive the second crossbeam 115 to move laterally left and right, completing the lateral movement operation when loading the wheelset.

[0151] The gripping mechanism of the truss manipulator 1 includes a second hydraulic cylinder 111, a third slider 113, a third guide rail 114, a second fixing block 112, and a lifting ring 118.

[0152] Two third guide rails 114 are fixed to both ends of the second crossbeam 115, and a third slider 113 slides on the third guide rails 114.

[0153] The upper side of the second fixing block 112 is connected to the third slider 113, and the lower side is fixed to the lifting ring 118. The lifting ring 118 is provided with a hollow U-shaped groove and a buffer pad is pasted on the inner side.

[0154] The second hydraulic cylinder 111 is installed in the second hydraulic cylinder support 110. The piston rods of the two second hydraulic cylinders 111 are connected to the outer ends of the two second fixed blocks 112. That is, when the piston rods of the two second hydraulic cylinders 111 extend, they drive the lifting rings 118 connected to the second fixed blocks 112 on both sides to move towards each other. When the piston rods of the two second hydraulic cylinders 111 retract, they drive the lifting rings 118 connected to the second fixed blocks 112 on both sides to move away from each other, thereby completing the gripping and placement of the wheelset.

[0155] The working process (usage method) of the fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to the present invention is as follows:

[0156] The initial position of the truss manipulator 1 is that the axis of its lifting ring 118 (the semi-circular groove part in the U-shaped groove) is aligned with the axis of the wheelset in the material pile;

[0157] Step S1. Loading the wheelset:

[0158] When the work begins, the piston rod of the second hydraulic cylinder 111 of the gripping mechanism extends, driving the lifting rings 118 to move towards each other to the clamping position;

[0159] Subsequently, the piston rods of the four first hydraulic cylinders 103 extend synchronously, driving the entire gripping mechanism and wheelset to rise vertically to the set position via the first crossbeam 107;

[0160] Next, the two second motors 108 start synchronously, and through the meshing transmission of the second gear 117 and the first rack 116, drive the second crossbeam 115 and the wheelset it grips to move laterally to above the starting section of the chain conveyor 4.

[0161] The first hydraulic cylinder 103 retracts, precisely placing the wheelset between the positioning blocks 403 of the chain 406, and then the lifting ring 118 is released and reset.

[0162] The reduction motor 405 of the chain conveyor 4 then starts, driving the chain 406 to move through the chain drive system, and transporting the wheelset to the inspection station;

[0163] Subsequently, the reduction motor 405 stops, the wheelset lifting and rotating mechanism 3 rises, lifting the wheelset away from the positioning block 403 of the chain 406, and driving the wheelset to rotate at a constant speed;

[0164] Step S2. Spray and magnetize the fluorescent magnetic suspension:

[0165] As the wheelset rotates, the spraying device 7 sprays fluorescent magnetic suspension liquid evenly onto its surface;

[0166] Subsequently, the composite magnetization mechanism 2 begins to work: its cylinder 203 piston rod extends, pushing the entire magnetization assembly forward, so that the electrode plate 208 is in close contact with the wheel set axle end;

[0167] First, the electromagnetic coil 211 is energized to magnetize the wheelset axially; after magnetization, the electromagnetic coil 211 is de-energized and the electrode plate 208 is energized to magnetize the wheelset circumferentially.

[0168] Step S3. Image acquisition and detection after magnetization:

[0169] After each magnetization is completed, the turn signal mechanism 6 and the rotation detection mechanism 5 start to work: the third motor 601 of the turn signal mechanism 6 drives the lamp fixing plate 605 and the lamp 606 to rotate to the optimal supplementary lighting angle through the gear pair;

[0170] Meanwhile, the seventh motor 810 on the gantry 8 drives the moving crossbeam 809 to descend to a predetermined height via a gear and rack pair, while the sixth motor 806 drives the rectangular connecting block 805 and its rotating detection mechanism 5 to move along the wheel set axis.

[0171] During this period, the fifth motor 504 drives the camera mount 501 to swing around the vertical axis, and the fourth motor 503 drives the camera 502 to pitch around the horizontal axis, thereby achieving 360° image acquisition of the wheel set surface without blind spots.

[0172] Step S4. Circular feeding and inspection of wheelsets:

[0173] While the first wheel is acquiring images, the gantry robot 1 simultaneously loads the second wheel pair, forming a continuous operation. After the first wheel pair is inspected, all actuators are reset, the chain conveyor 4 sends it out, and at the same time sends the second wheel pair into the inspection station. This cycle is repeated to achieve continuous automated inspection.

Claims

1. A fluorescent magnetic particle non-destructive testing device for surface defects of high-speed train wheelsets, characterized in that: It includes a gantry robot (1), a composite magnetization mechanism (2), a wheelset lifting and rotating mechanism (3), a chain conveyor (4), a rotation detection mechanism (5), a turn signal mechanism (6), a spray device (7), a gantry (8), a liquid collection tank (9), and a base (10). The truss manipulator device (1) includes: a longitudinal movement mechanism, a lateral movement mechanism, and a gripping mechanism; The chain conveyor (4) is fixed in the middle of the base (10), and the composite magnetization mechanism (2) is located at both ends of the base (10); The gantry (8) is located above the base (10), and the rotation detection mechanism (5), the turn signal mechanism (6) and the spray device (7) are all installed on the gantry (8); The chain conveyor (4) is provided with a liquid collection tank (9) on its lower side, and the wheel pair lifting and rotating mechanism (3) is installed in the middle of the inner side of the liquid collection tank (9); The composite magnetization mechanism (2) includes a support (201), a back plate (202), a cylinder (203), a C-shaped connecting block (207), an electrode plate (208), an electromagnet core (209), a coil tube (210), and an electromagnetic coil (211). The support (201) is installed on the base (10), and it has a hollow structure with a back plate (202) on the outside. The inner side of the back plate (202) is fixed to the cylinder (203).

2. The fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to claim 1, characterized in that: The outer side of the coil tube (210) is provided with a C-shaped connecting block (207), which slides against the inner wall of the support (201); The coil drum (210) is connected inward to the piston rod of the cylinder (203); An electromagnetic coil (211) is wound on a coil tube (210), an electromagnet core (209) is fixed on the inner surface of the coil tube (210), and an electrode plate (208) is fixed on the front end of the electromagnet core (209). The piston rod of the cylinder (203) extends out and presses against both ends of the shaft of the wheelset. The electromagnetic coil (211) is energized to complete the axial magnetization of the wheelset. When the electromagnetic coil (211) is de-energized, the electrode plate (208) is energized to complete the circumferential magnetization of the wheelset.

3. The fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to claim 2, characterized in that: The rotation detection mechanism (5) is mounted on a rectangular connecting block (805) and includes: a camera mounting bracket (501), a camera (502), a fourth motor (503), a fifth motor (504), and a vertical plate (505). The fifth motor (504) is fixed at the lower end of the rectangular connecting block (805), and its output shaft is fixedly connected to the camera mounting bracket (501); The camera (502) is axially connected to the camera mount (501) at both ends, and its rotating shaft is perpendicular to the output shaft of the fifth motor (504); The camera (502) is driven to rotate by a fourth motor (503) on one side of the camera mount (501); The fifth motor (504) drives the camera mount (501) to rotate around the vertical axis from -90° to 90°, and the fourth motor (503) drives the camera (502) to rotate around the horizontal axis from -90° to 90°.

4. The fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to claim 3, characterized in that: The turn signal mechanism (6) includes a third motor (601), a lamp mounting plate (605), and a lamp (606); The third motor (601) is fixed to the upper end of the gantry (8); The two ends of the lamp fixing plate (605) are axially connected to the middle of the gantry frame (8), and a strip lamp (606) is installed on it. The third motor (601) drives the lamp mounting plate (605) to rotate from -90° to 90°.

5. A fluorescent magnetic particle non-destructive testing device for surface defects of high-speed train wheelsets according to claim 3 or 4, characterized in that: The chain conveying device (4) includes a support base (401), a sprocket (402), a positioning block (403), a drive shaft (404), a geared motor (405), a chain (406), and a support plate (407). The support bases (401) are arranged in a rectangular shape, with a pair on each of the left and right sides and fixed to the ground. Each pair of support bases (401) is axially connected to a drive shaft (404). Both the inner and outer ends of the drive shaft (404) are fixed to sprockets (402), and the inner and outer sprockets (402) are respectively connected by chains (406) on both sides; Each link of the chain (406) is fixed with a positioning block (403), and two pairs of support plates (407) are provided on the inner and outer sides. The upper edge of the support plate (407) slides into the corresponding position of the chain (406); One of the two drive shafts (404) is connected to the output shaft of the geared motor (405); The gantry manipulator (1) places the wheelset on the chain (406), and the wheel rim of the wheelset is attached to the positioning block (403) to achieve positioning. The geared motor (405) is powered on to drive the chain (406) to move. When the wheelset is transferred to the detection position, the geared motor (405) is de-energized, the chain (406) stops moving, the wheelset lifting and rotating mechanism (3) is raised until the wheelset is separated from the chain (406) by a certain distance and drives the wheelset to rotate. Then, the wheelset is sprayed with fluorescent magnetic suspension, magnetized, and image acquired and detected in sequence.

6. The fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to claim 5, characterized in that: The gantry (8) includes a fourth guide rail (801), a fourth slider (803), a stop block (804), a rectangular connecting block (805), a sixth motor (806), a fifth slider (808), a moving crossbeam (809), a seventh motor (810), and a fifth guide rail (812). The gantry frame (8) has vertical fourth guide rails (801) on both sides, and a fourth slider (803) slides on the fourth guide rails (801). A stop block (804) is provided at the top. The fourth sliders (803) on both sides are fixedly connected to both ends of the movable crossbeam (809); The movable crossbeam (809) is perpendicular to the fourth guide rail (801), and a seventh motor (810) is installed at both ends of the crossbeam. The seventh motor (810) synchronously drives the movable crossbeam (809) to move up and down. A fifth guide rail (812) is installed parallel to the moving crossbeam (809), and the fifth slider (808) slides on the fifth guide rail (812); A rectangular connecting block (805) is fitted onto a movable crossbeam (809), and its upper inner end is fixedly connected to the upper end of the fifth slider (808); A sixth motor (806) is installed on one side of the rectangular connecting block (805), which enables the rectangular connecting block (805) to move along the long side of the moving crossbeam (809).

7. The fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to claim 6, characterized in that: The longitudinal moving mechanism includes a column (101), a first slider (104), a first guide rail (102), a first hydraulic cylinder (103), and a first crossbeam (107). A pair of guide rails (102) are fixed to the ground on both the inner and outer sides of the column (101). The first slider (104) slides on the first guide rail (102), and the first slider (104) on the same side is fixed to both ends of the first crossbeam (107); The first crossbeam (107) is perpendicular to the first guide rail (102). A first hydraulic cylinder (103) is provided below the first crossbeam (107) on both sides. The first hydraulic cylinders (103) on both sides are driven synchronously to make the first crossbeam (107) on both sides move up and down longitudinally synchronously; to complete the lifting operation when loading wheelset.

8. The fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to claim 7, characterized in that: The lateral movement mechanism of the truss manipulator (1) includes a second guide rail (106), a second motor (108), a second slider (119), a first rack (116), a second gear (117), and a second crossbeam (115). The first crossbeam (107) on both sides is horizontally fixed with the second guide rail (106), and the two ends of the second crossbeam (115) are fixed with the second slider (119). The second slider (119) slides with the second guide rail (106) on both sides respectively, and the second crossbeam (115) is set perpendicular to the second guide rail (106). The second crossbeam (115) is equipped with a second motor (108) at both ends, and the output shaft of the second motor (108) is equipped with a second gear (117). The first crossbeam (107) is fixed to the outer side of the first transverse rack (116), the second gear (117) meshes with the first rack (116), and the second motors (108) on both sides synchronously drive the second crossbeam (115) to move laterally left and right.

9. The fluorescent magnetic particle non-destructive testing equipment for surface defects of high-speed train wheelsets according to claim 8, characterized in that: The gripping mechanism of the truss manipulator (1) includes a second hydraulic cylinder (111), a third slider (113), a third guide rail (114), a second fixing block (112), and a lifting ring (118). Two third guide rails (114) are fixed to both ends of the second crossbeam (115), and a third slider (113) slides on the third guide rails (114). The third slider (113) has a lifting ring (118) on its lower side, and the lifting ring (118) has a hollow U-shaped groove and a buffer pad is pasted on its inner side; The second hydraulic cylinder (111) is installed at both ends of the second crossbeam (115) to drive the two side lifting rings (118) to move towards each other and away from each other.

10. A method for non-destructive testing of surface defects in high-speed train wheelsets using fluorescent magnetic particle, characterized in that: A fluorescent magnetic particle non-destructive testing device for surface defects of motor vehicle wheelsets is used, and the steps are as follows: S1. Loading of wheelsets: The piston rod of the second hydraulic cylinder (111) of the gripping mechanism extends, driving the lifting rings (118) to move towards each other to the clamping position; The piston rods of the four first hydraulic cylinders (103) extend synchronously, and drive the entire gripping mechanism and wheelset to rise vertically to the set position through the first crossbeam (107); Two second motors (108) start synchronously and drive the second crossbeam (115) and the wheelset it grips to move laterally above the starting section of the chain conveyor (4) through the meshing transmission of the second gear (117) and the first rack (116); The first hydraulic cylinder (103) retracts, precisely placing the wheelset between the positioning blocks (403) of the chain (406), and then the lifting ring (118) is released and reset; The geared motor (405) of the chain conveyor (4) then starts, driving the chain (406) to move through the chain drive system, and transporting the wheelset to the inspection station; When the geared motor (405) stops, the wheelset lifting and rotating mechanism (3) rises, lifting the wheelset off the positioning block (403) of the chain (406), and driving the wheelset to rotate at a constant speed. S2. Spray and magnetize the fluorescent magnetic suspension: While the wheelset is rotating, the spraying device (7) sprays fluorescent magnetic suspension liquid evenly onto its surface; The composite magnetization mechanism (2) starts working: its cylinder (203) piston rod extends, pushing the entire magnetization assembly forward, so that the electrode plate (208) is in close contact with the wheel set shaft end; The electromagnetic coil (211) is energized to axially magnetize the wheelset; after magnetization, the electromagnetic coil (211) is de-energized and the electrode plate (208) is energized to circumferentially magnetize the wheelset. S3. Image acquisition and detection after magnetization: After each magnetization is completed, the turn signal mechanism (6) and the rotation detection mechanism (5) start to work: the third motor (601) of the turn signal mechanism (6) drives the lamp fixing plate (605) and the lamp (606) to rotate to the optimal supplementary lighting angle through the gear pair; Meanwhile, the seventh motor (810) on the gantry (8) drives the moving crossbeam (809) to descend to a predetermined height through a gear and rack pair, while the sixth motor (806) drives the rectangular connecting block (805) and its rotating detection mechanism (5) to move along the wheel pair axis. During this period, the fifth motor (504) drives the camera mount (501) to swing around the vertical axis, and the fourth motor (503) drives the camera (502) to pitch around the horizontal axis, thereby achieving 360° image acquisition of the wheel set surface without blind spots; S4. Circular feeding and inspection of wheelsets: While the first wheel is being image acquired, the gantry robot (1) simultaneously loads the second wheel pair, forming a continuous operation. After the first wheel pair is inspected, all actuators are reset, the chain conveyor (4) sends it out, and at the same time sends the second wheel pair into the inspection station. This cycle continues, and the inspection is automated.

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