A real-time detection device for the height of surface overlay welds on shafts

Abstract

This invention relates to the field of detection device technology, specifically a real-time detection device for the height of weld seams on shaft surfaces. It includes a base frame on which a multi-axis drive platform is mounted. A welding frame and a detection frame are connected to the multi-axis drive platform. A cooling spray pipe is also included and fixed to the multi-axis drive platform. A laser welding gun, an industrial camera, and an infrared thermometer are fixedly mounted on the welding frame. A pressure frame is slidably connected to the detection frame and a reciprocating pressure module is fixedly mounted thereon. The reciprocating pressure module drives the pressure frame to vibrate vertically with varying amplitude. A slide is slidably connected to the pressure frame, and a friction transmission module drives the slide to vibrate horizontally with varying amplitude between the pressure frame and the slide. The beneficial effects of this invention are: by integrating the welding frame, detection frame, and cooling spray pipe into a single motion system through an integrated multi-axis drive platform, and in conjunction with a double-rod hydraulic cylinder and a linear transmission module, welding, spray cooling, weld seam cleaning, and height detection can be completed sequentially without moving the workpiece.

Description

Technical Field

[0001] This invention relates to the field of detection device technology, specifically to a real-time detection device for the height of weld seams on the surface of shafts. Background Technology

[0002] In the field of shaft parts manufacturing and repair, surface surfacing welding technology is widely used in key areas such as engineering machinery, aerospace, and energy equipment because it can significantly improve the wear resistance, corrosion resistance, and strength of shaft parts. The weld quality of shaft parts directly determines the operational stability and service life of equipment. Among them, weld height is a core quality indicator, and its detection accuracy and timeliness are crucial to subsequent assembly accuracy, load-bearing capacity, and fatigue resistance. For example, patent application CN108335286A discloses an online visual inspection method for weld formation based on dual-line structured light, which can achieve good results even when the base plate is uneven, such as with surfacing welding; it can also achieve functionality when the base plate is flat. The method of this invention can effectively improve calibration accuracy and 3D reconstruction accuracy, and perform multi-angle analysis of weld formation results.

[0003] There are currently many technical problems in the detection of weld height on the surface of shafts and related supporting processes:

[0004] Existing technologies struggle to achieve integrated, simultaneous welding, cooling, cleaning, and inspection. Disconnected processes lead to poor weld quality control, delayed inspection data, and an inability to adjust process parameters in real time to address temperature changes and initial defects during welding. This can easily result in weld cracking, slag residue, and uneven weld height. Specifically, existing equipment for shaft surface welding typically employs a segmented operation mode of welding, cooling, transport, cleaning, and inspection. After welding, the workpiece must be manually transported to a cooling area, then to cleaning equipment for slag removal, and finally, a dedicated inspection instrument is used to check the weld height. This segmented approach has significant drawbacks: firstly, the transport process between processes not only reduces production efficiency but can also cause weld deformation due to collisions or improper placement during transport, affecting the accuracy of subsequent inspections; secondly, key data such as weld temperature changes and initial morphological defects cannot be fed back to subsequent processes in real time, cooling water volume is set based on experience, cleaning intensity lacks targeted adjustment, and inspection results only reflect the final weld state, failing to trace parameter deviations during welding, resulting in extremely poor weld quality control.

[0005] Based on this, the present invention provides a real-time detection device for the height of surface weld overlay on shafts to solve the problems mentioned in the background art. Summary of the Invention

[0006] This invention addresses the technical problems existing in the prior art by providing a real-time detection device for the height of weld seams on the surface of shafts. This solves the problem that the prior art is unable to achieve integrated and synchronous operation of welding, cooling, cleaning and detection. The disconnect between each process leads to poor controllability of weld quality, delayed detection data, and the inability to adjust process parameters in real time for temperature changes and initial defects during the welding process, which easily causes problems such as weld cracking, slag residue and uneven height.

[0007] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A real-time detection device for the height of surface surfacing welds on shafts includes a base frame on which a multi-axis drive platform is mounted, and a welding frame and a detection frame are respectively connected to the multi-axis drive platform:

[0008] It also includes cooling nozzles, which are fixed to a multi-axis drive platform;

[0009] The welding frame is equipped with a laser welding gun, an industrial camera, and an infrared thermometer.

[0010] A pressure frame is slidably connected to the inspection frame and a reciprocating pressure module is fixedly installed. The reciprocating pressure module drives the pressure frame to vibrate vertically with varying amplitude. A slide is slidably connected to the pressure frame. A friction transmission module that drives the slide to vibrate horizontally with varying amplitude is provided between the pressure frame and the slide. A rotating brush shaft is driven to the friction transmission module. The rotating brush shaft is rotatably connected to the slide. The top of the rotating brush shaft is evenly distributed with steel wire bristles and has an array of high-pressure hot spray holes. A leveling rubber wheel rotates on the slide.

[0011] A probe plate is fixed on the inspection rack, and three detection modules are arrayed on the probe plate.

[0012] The detection module includes a probe rod slidably connected to the probe plate and a displacement sensor fixed to the probe plate. The monitoring end of the displacement sensor faces the probe rod. A limit ring is fixed on the probe rod, and a compression spring is connected between the limit ring and the probe plate. A detection steel ball is embedded at the end of the probe rod.

[0013] It also includes two symmetrically arranged pipe clamp modules, each holding a workpiece to be welded.

[0014] Based on the above technical solution, the present invention can be further improved as follows.

[0015] As a preferred technical solution of the present invention, the multi-axis drive platform includes a linear transmission module mounted on a base frame, a shift frame connected to the linear transmission module, a welding frame and an inspection frame slidably connected to the shift frame, a double-outlet hydraulic cylinder mounted on the shift frame, the two movable ends of the double-outlet hydraulic cylinder being fixedly connected to the welding frame and the shift frame respectively, the axis of the double-outlet hydraulic cylinder being perpendicular to the transmission direction of the linear transmission module, and the cooling nozzle being fixedly mounted on the shift frame.

[0016] As a preferred technical solution of the present invention, the surface array of the cooling nozzle is provided with spray heads facing the workpiece to be welded, a metal corrugated pipe is fixedly connected to the cooling nozzle, a sludge collection box with an open top is installed at the bottom of the base frame, a central control unit is installed on the end face of the base frame, and the data terminals of the industrial camera, infrared thermometer and displacement sensor are all connected to the central control unit.

[0017] As a preferred technical solution of the present invention, the pipe clamp module includes a rotary motor fixedly installed on the base frame and a three-jaw clamp rotatably connected to the base frame. The three-jaw clamp is used to clamp the workpiece to be welded. A first transmission belt is drivenly connected to the output shaft of the rotary motor, and the first transmission belt is drivenly connected to the three-jaw clamp.

[0018] As a preferred technical solution of the present invention, the reciprocating pressure module includes a servo motor mounted on a test rack, a vertical slide table slidably connected to the test rack, a first driven roller and a transmission shaft rotatably connected to the pressure frame. A first cam disk is mounted on the output shaft of the servo motor. Four first protrusions are arranged in an array along the circumferential direction on the first cam disk. The four first protrusions are alternately connected to the first driven roller, and the transmission stroke of the four first protrusions to the first driven roller is different. A first pulley is rotatably connected to the vertical slide table. A vertical spring is mounted on the side of the vertical slide table. The other end of the vertical spring is fixedly connected to the test rack. A second transmission belt is drivenly connected to the output shaft of the servo motor. Both the first pulley and the transmission shaft are drivenly connected to the second transmission belt.

[0019] As a preferred embodiment of the present invention, the friction transmission module includes a camshaft rotatably connected to a pressure frame and a second driven roller rotatably connected to a slide. A second cam disk is mounted on the camshaft, and four second protrusions are arranged in an array along the circumferential direction on the second cam disk. The four second protrusions are alternately connected to the second driven roller, and the transmission stroke of the four second protrusions to the second driven roller is different. Both the camshaft and the transmission shaft are equipped with linkage bevel gears, and two linkage bevel gears are orthogonally meshed. A horizontal slide is slidably connected to the pressure frame, and a second pulley is rotatably connected to the horizontal slide. A horizontal spring is mounted on the side of the horizontal slide, and the other end of the horizontal spring is fixedly connected to the pressure frame. A third transmission belt is drivenly connected to the camshaft, and the second pulley and the rotating brush shaft are both drivenly connected to the third transmission belt.

[0020] As a preferred technical solution of the present invention, the device further includes a hot air blower, wherein a filter is installed at the air inlet port of the hot air blower, a heat pump pipe is connected to the air outlet port of the hot air blower, a hot flow channel is opened inside the rotating brush shaft, and the air outlet port of the heat pump pipe and the tail end of the high-pressure hot spray hole are both connected to the hot flow channel.

[0021] As a preferred technical solution of the present invention, the industrial camera and the infrared thermometer are symmetrically arranged on both sides of the laser welding gun. The axes of the laser welding gun and the rotating brush shaft are both perpendicular to the axis of the workpiece to be welded. The laser welding gun is positioned directly above the workpiece to be welded, and the rotating brush shaft is positioned directly below the workpiece to be welded. The angle between the axis of the measurement and control end of the industrial camera and the infrared thermometer and the axis of the laser welding gun is 45°.

[0022] As a preferred technical solution of the present invention, the axis of the leveling rubber wheel is parallel to the axis of the workpiece to be welded, the leveling rubber wheel is made of high temperature resistant silicone rubber, and its surface is coated with a polytetrafluoroethylene anti-stick coating.

[0023] The beneficial effects of this invention are:

[0024] 1. Traditional shaft welding processes employ a segmented operation mode of welding, cooling, transportation, cleaning, and inspection. The process relies on manual transportation between steps, which is inefficient and prone to weld deformation due to collisions or improper placement. This invention integrates modules such as welding frame, inspection frame, and cooling spray pipe into the same motion system through an integrated multi-axis drive platform. With the help of a double-outlet hydraulic cylinder and linear transmission module, welding, spray cooling, weld cleaning, and height inspection can be completed sequentially without moving the workpiece. This achieves fully automated and synchronized operation, significantly improving production efficiency and weld quality controllability, and solving the problems of process fragmentation and data feedback lag in the traditional mode.

[0025] 2. By using industrial cameras and infrared thermometers symmetrically arranged on both sides of the laser welding gun, this invention can simultaneously collect initial morphological data and real-time temperature information of the weld and transmit them to the central control unit. The system dynamically adjusts the spray volume of the cooling nozzle according to temperature changes, and combines the hot air blower and high-pressure hot nozzles to provide thermal assistance for the cleaning process, forming a closed-loop control link of welding, monitoring, cooling and cleaning. This design enables the device to respond in real time to the temperature fluctuations and surface condition of the weld, adjust process parameters in a timely manner, and effectively prevent problems such as weld cracking, slag residue and uneven height, achieving a leap from post-detection to process control.

[0026] 3. This invention drives the pressure frame to vibrate vertically with varying amplitude through a reciprocating pressure module and the slide to vibrate horizontally with varying amplitude through a friction transmission module. The rotating brush shaft has a composite motion trajectory in both vertical and horizontal directions while rotating. This multi-degree-of-freedom vibration cleaning method, combined with the pre-leveling of the leveling rubber wheel and the softening of welding slag with the assistance of hot air, can remove residues from the surface of the weld and the dead corners on both sides. It can also adapt to the micro-morphological changes of different weld areas, avoiding the problems of incomplete cleaning or excessive damage to the weld caused by traditional fixed pressure cleaning. This provides a uniform and clean surface foundation for subsequent height inspection.

[0027] 4. In this invention, three independent detection modules are arrayed on the inspection rack. Each module adopts a combination structure of a probe, a compression spring, and a displacement sensor. By detecting the contact between the steel ball and the weld surface and reading the displacement data in real time, the three-point synchronous detection can comprehensively reflect the height distribution characteristics of the weld cross section, avoiding the random errors of single-point detection. The spring mechanism ensures that the probe quickly resets after detection, ensuring the stability of continuous detection. The detection data is uploaded to the central control unit in real time, realizing online, multi-point, and high-precision measurement of weld height, providing a reliable basis for process optimization and quality assessment. Attached Figure Description

[0028] Figure 1 A schematic diagram of a device for real-time detection of the height of surface weld overlays on shafts;

[0029] Figure 2 for Figure 1 A schematic diagram of the structure from the rear-view perspective;

[0030] Figure 3 This is a schematic diagram of the cooling nozzle and infrared thermometer.

[0031] Figure 4 for Figure 3 A magnified schematic diagram of the partial structure at point A in the middle;

[0032] Figure 5 for Figure 3 A magnified schematic diagram of the local structure at point B;

[0033] Figure 6 This is a schematic diagram of the probe and displacement sensor.

[0034] Figure 7 A schematic diagram of the structure of the leveling rubber wheel and the carriage;

[0035] Figure 8 for Figure 7 A schematic diagram of the cross-sectional structure;

[0036] Figure 9 for Figure 8 A magnified schematic diagram of the structure at point C.

[0037] The attached diagram lists the components represented by each number as follows:

[0038] 1. Base frame; 2. Welding frame; 3. Inspection frame; 4. Cooling nozzle; 5. Laser welding torch; 6. Industrial camera; 7. Infrared thermometer; 8. Pressure frame; 9. Slide frame; 10. Rotary brush shaft; 11. Steel wire brush bristles; 12. High-pressure hot spray nozzle; 13. Leveling rubber wheel; 14. Probe plate; 15. Probe rod; 16. Displacement sensor; 17. Limiting ring; 18. Compression spring; 19. Detection steel ball; 20. Workpiece to be welded; 21. Linear transmission module; 22. Shifting frame; 23. Double-outlet hydraulic cylinder; 24. Metal wave 25. Connecting pipe; 26. Central control unit; 27. Rotary motor; 28. Three-jaw clamp; 29. ​​Servo motor; 30. Vertical slide; 31. First driven roller; 32. Drive shaft; 33. First cam plate; 34. First pulley; 35. Vertical spring; 36. Camshaft; 37. Second driven roller; 38. Second cam plate; 39. Second protrusion; 40. Horizontal slide; 41. Second pulley; 42. Horizontal spring; 43. Hot air blower; 44. Sewage collection box. Detailed Implementation

[0039] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0040] The present invention provides the following preferred embodiments, such as Figures 1-9 As shown, a real-time detection device for the height of surface surfacing welds on shafts includes a base frame 1 on which a multi-axis drive platform is mounted. A welding frame 2 and a detection frame 3 are respectively connected to the multi-axis drive platform.

[0041] It also includes a cooling nozzle 4, which is fixed on a multi-axis drive platform;

[0042] The multi-axis drive platform includes a linear transmission module 21 mounted on a base frame 1. A shift frame 22 is connected to the linear transmission module 21. The welding frame 2 and the inspection frame 3 are slidably connected to the shift frame 22. A double-outlet hydraulic cylinder 23 is mounted on the shift frame 22. The two movable ends of the double-outlet hydraulic cylinder 23 are fixedly connected to the welding frame 2 and the shift frame 22 respectively. The axis of the double-outlet hydraulic cylinder 23 is perpendicular to the transmission direction of the linear transmission module 21. A cooling nozzle 4 is fixedly mounted on the shift frame 22.

[0043] A metal corrugated pipe 24 is fixedly connected to the cooling nozzle 4. A flange connector is provided at the top of the metal corrugated pipe 24. During operation, the flange connector is connected to an external cooling water source, and the external water source supplies cooling water.

[0044] The multi-axis drive platform drives the moving frame 22 to move along the workpiece axis direction through the linear transmission module 21. With the help of the double-outlet hydraulic cylinder 23, the distance between the welding frame 2 and the inspection frame 3 is adjusted. It can flexibly adapt to shaft workpieces of different lengths and diameters, and realize the integrated synchronous operation of welding, inspection and cooling processes.

[0045] The cooling nozzle 4 is connected to the external water source through the metal corrugated pipe 24. The deformable characteristics of the metal corrugated pipe 24 do not restrict the degree of freedom of movement of the moving frame 22. The flange connection ensures the sealing and stability of the water supply, avoids water leakage and supply interruption during the cooling process, and significantly improves the continuity of operation and adaptability of the device.

[0046] It also includes two symmetrically arranged pipe clamp modules, each of which holds the workpiece 20 to be welded.

[0047] The pipe clamp module includes a rotary motor 26 fixedly mounted on the base frame 1 and a three-jaw clamp 27 rotatably connected to the base frame 1. The three-jaw clamp 27 is used to clamp the workpiece 20 to be welded. A first transmission belt is driven to the output shaft of the rotary motor 26, and the first transmission belt is driven to the three-jaw clamp 27.

[0048] The workpiece 20 to be welded is a shaft-type part. Before welding, the two workpieces 20 to be welded are joined together. During welding, the two rotary motors 26 work synchronously. After the rotary motors 26 work, the two workpieces 20 to be welded rotate counterclockwise synchronously.

[0049] The three-jaw clamp 27 features strong clamping and high centering, which can accurately fix the shaft-type workpiece 20 to be welded, and effectively avoid the misalignment of the weld caused by the workpiece shifting during the welding process.

[0050] The rotary motor 26 drives the three-jaw clamp 27 to rotate synchronously through the first transmission belt, ensuring that the workpiece 20 to be welded rotates at a uniform speed. Together with the laser welding gun 5, it completes the continuous welding of the annular weld. This solves the problems of uneven weld width and inconsistent penetration caused by unstable clamping and asynchronous rotation during the welding of annular welds of shaft parts, and provides a uniform basis for subsequent weld height detection.

[0051] The welding frame 2 is fixedly equipped with a laser welding gun 5, an industrial camera 6, and an infrared thermometer 7;

[0052] The industrial camera 6 and the infrared thermometer 7 are symmetrically arranged on both sides of the laser welding gun 5. The axes of the laser welding gun 5 and the rotating brush shaft 10 are perpendicular to the axis of the workpiece 20 to be welded. The laser welding gun 5 is positioned directly above the workpiece 20 to be welded. The angle between the axis of the measurement and control end of the industrial camera 6 and the infrared thermometer 7 and the axis of the laser welding gun 5 is 45°.

[0053] During welding, the laser welding gun 5 is connected to an external welding machine. The laser welding gun 5 performs welding operations on the connection seam of the two workpieces 20 to be welded. After the laser welding gun 5 finishes welding, as the workpieces 20 to be welded rotate, the weld seam first undergoes natural cooling. Then, it moves to the action area of ​​the cooling nozzle 4 to perform spray cooling of the weld seam.

[0054] After welding is completed, the industrial camera 6 detects the initial weld height in real time, and the infrared thermometer 7 detects the weld temperature in real time and adjusts the cooling water supply of the cooling nozzle 4 per unit time.

[0055] The laser welding gun 5 is positioned directly above the workpiece, allowing for vertical focusing of the welding area and ensuring uniform weld depth.

[0056] The industrial camera 6 and the infrared thermometer 7 are symmetrically arranged on both sides of the laser welding gun 5 at a 45° angle. This angle design can avoid the obstruction of welding sparks and spatter, ensuring that both can accurately collect the initial shape of the weld and real-time temperature data.

[0057] After the data is transmitted to the central control unit 25 in real time, the cooling water supply of the cooling nozzle 4 can be adjusted immediately, forming a closed-loop control of welding, monitoring, and cooling adjustment. This allows for the early detection of initial defects and temperature anomalies in the weld, providing accurate data support for subsequent cleaning and inspection processes, and significantly improving the controllability of the welding process and the basic quality of the weld.

[0058] A pressure frame 8 is slidably connected to the inspection frame 3 and a reciprocating pressure module is fixedly installed on it. The reciprocating pressure module drives the pressure frame 8 to vibrate vertically with varying amplitude. A slide 9 is slidably connected to the pressure frame 8. A friction transmission module that drives the slide 9 to vibrate horizontally with varying amplitude is provided between the pressure frame 8 and the slide 9. A rotating brush shaft 10 is connected to the friction transmission module. The rotating brush shaft 10 is rotatably connected to the slide 9. The rotating brush shaft 10 is located directly below the workpiece 20 to be welded. The top of the rotating brush shaft 10 is evenly distributed with steel wire bristles 11 and is arrayed with high-pressure hot spray holes 12. A leveling rubber wheel 13 rotates on the slide 9.

[0059] The axis of the leveling roller 13 is parallel to the axis of the workpiece 20 to be welded. The leveling roller 13 is made of high temperature resistant silicone rubber and its surface is coated with a polytetrafluoroethylene anti-stick coating.

[0060] The device also includes a hot air blower 43, with a filter installed at the air inlet of the hot air blower 43 and a heat pump pipe connected to the air outlet of the hot air blower 43. A hot flow channel is opened inside the rotating brush shaft 10, and the air outlet of the heat pump pipe and the tail end of the high-pressure hot spray hole 12 are both connected to the hot flow channel.

[0061] After the cooling nozzle 4 initially cools the weld, the leveling roller 13 then comes into contact with the weld. By adjusting the material and clamping state of the leveling roller 13, pressure is used to assist in the discharge of welding slag and to improve the flatness of the weld, thereby facilitating the accurate detection of the weld height.

[0062] After the leveling rubber wheel 13 has finished treating the weld seam, the rotating brush shaft 10 is used to clean the weld seam.

[0063] The leveling roller 13 is made of high-temperature resistant rubber and coated with polytetrafluoroethylene anti-stick coating. It not only avoids sticking to the high-temperature weld, but also helps to remove the weld slag through reasonable clamping force. At the same time, it performs preliminary leveling of the weld surface, clearing away surface protrusions to eliminate interference for subsequent accurate inspection.

[0064] The steel wire bristles 11 of the rotating brush shaft 10 work together to clean the weld. The clean hot air generated by the hot air blower 43 is sprayed out from the high-pressure hot air nozzle 12 through the hot flow channel. On the one hand, it can soften the residual welding slag on the surface of the weld and improve the thoroughness of cleaning. On the other hand, it can prevent the weld from cooling down too quickly after the initial cooling and causing cracks. It achieves the dual effect of cleaning and crack prevention, and solves the technical problems of traditional cleaning not being clean and welds being prone to cracking after secondary cooling.

[0065] The hot air generated by the hot air blower 43 is 90℃ to prevent secondary oxidation of the weld.

[0066] The reciprocating pressure module includes a servo motor 28 mounted on the inspection frame 3, a vertical slide 29 slidably connected to the inspection frame 3, a first driven roller 30 rotatably connected to the pressure frame 8, and a transmission shaft 31. A first cam disk 32 is mounted on the output shaft of the servo motor 28. Four first protrusions 33 are arranged in an array along the circumferential direction on the first cam disk 32. The four first protrusions 33 are alternately connected to the first driven roller 30, and the transmission stroke of the four first protrusions 33 to the first driven roller 30 is different. A first pulley 34 is rotatably connected to the vertical slide 29. A vertical spring 35 is mounted on the side of the vertical slide 29. The other end of the vertical spring 35 is fixedly connected to the inspection frame 3. A second transmission belt is drivenly connected to the output shaft of the servo motor 28. The first pulley 34 and the transmission shaft 31 are both drivenly connected to the second transmission belt.

[0067] When the servo motor 28 drives the first cam disk 32 to rotate, the four first protrusions 33 with different transmission strokes alternately contact the first driven roller 30, driving the pressure frame 8 to achieve vertical amplitude vibration, rather than a single fixed pressure output;

[0068] The vertical spring 35 ensures that the pressure frame 8 maintains a reasonable fit with the weld during vibration. This dynamic pressure method can adapt to the small protrusions at different positions of the weld, making the leveling force of the leveling wheel 13 and the cleaning force of the rotating brush shaft 10 more targeted. It avoids the problem of insufficient local pressure under fixed pressure leading to incomplete cleaning or excessive pressure leading to weld damage, and significantly improves the uniformity and adaptability of weld treatment.

[0069] The friction transmission module includes a camshaft 36 rotatably connected to the pressure frame 8 and a second driven roller 37 rotatably connected to the slide 9. A second cam disk 38 is mounted on the camshaft 36. Four second protrusions 39 are arranged in a circumferential array on the second cam disk 38. The four second protrusions 39 are alternately connected to the second driven roller 37, and the transmission stroke of the four second protrusions 39 to the second driven roller 37 is different. Both the camshaft 36 and the transmission shaft 31 are equipped with linkage bevel gears. The two linkage bevel gears are orthogonally meshed. A horizontal slide 40 is slidably connected to the pressure frame 8. A second pulley 41 is rotatably connected to the horizontal slide 40. A horizontal spring 42 is mounted on the side of the horizontal slide 40. The other end of the horizontal spring 42 is fixedly connected to the pressure frame 8. A third transmission belt is drivenly connected to the camshaft 36. The second pulley 41 and the rotating brush shaft 10 are both drivenly connected to the third transmission belt.

[0070] The drive shaft 31 transmits power to the camshaft 36 through a linkage bevel gear, realizing the efficient conversion of vertical vibration power to horizontal vibration power. The structure is compact and the transmission is stable.

[0071] The four protrusions of the second cam disk 38 with different strokes drive the slide 9 to vibrate horizontally with varying amplitude. This, together with the rotation of the rotating brush shaft 10, forms a composite motion trajectory of rotating cleaning and horizontal oscillation, which expands the cleaning coverage of the wire brush bristles 11 and can accurately remove the dead corner weld slag on both sides of the weld.

[0072] The horizontal spring 42 ensures that the slide 9 always fits the weld surface during vibration. Compared with single rotation cleaning, the cleaning effect of compound motion is more thorough and without omission, further improving the cleanliness and smoothness of the weld surface.

[0073] A probe plate 14 is fixedly mounted on the inspection rack 3, and three detection modules are arrayed on the probe plate 14.

[0074] The detection module includes a probe rod 15 slidably connected to the probe plate 14 and a displacement sensor 16 fixed to the probe plate 14. The monitoring end of the displacement sensor 16 faces the probe rod 15. A limit ring 17 is fixedly installed on the probe rod 15, and a compression spring 18 is connected between the limit ring 17 and the probe plate 14. A detection steel ball 19 is embedded at the end of the probe rod 15.

[0075] The probe 15 is made of cemented carbide, and the detection steel ball 19 is made of silicon nitride ceramic.

[0076] After the rotating brush shaft 10 finishes cleaning the weld, the three detection modules perform multi-point synchronous detection on the weld and simultaneously obtain multiple sets of detection data.

[0077] The surface array of the cooling nozzle 4 is provided with spray heads facing the workpiece 20 to be welded. The bottom of the base frame 1 is equipped with a sludge collection box 44 with an open top. The end face of the base frame 1 is equipped with a central control unit 25. The data terminals of the industrial camera 6, infrared thermometer 7 and displacement sensor 16 are all connected to the central control unit 25.

[0078] The central control unit 25 is a Siemens S7-1200 PLC, which integrates data acquisition, processing and control functions;

[0079] The array of three detection modules enables multi-point synchronous detection of weld height. Compared with traditional single-point detection, it can more comprehensively reflect the overall height distribution of the weld and avoid errors caused by local detection.

[0080] The low friction when the detection steel ball 19 contacts the weld reduces damage to the weld surface. The cooperation between the spring and the limiting ring 17 ensures that the probe 15 quickly resets after detection, ensuring the continuity and stability of the detection process.

[0081] The displacement sensor 16 converts the physical displacement signal into an electrical signal, which is then processed by the central control unit 25 and outputs the detection result in real time, thereby realizing real-time feedback of the weld height.

[0082] The 44 waste collection boxes collect cooling wastewater and welding slag, preventing pollution of equipment and the working environment. The whole system realizes the integration of multi-point accurate detection, real-time data processing and environmentally friendly collection, solving the problems of low detection accuracy, data lag and environmental pollution in traditional detection.

[0083] The workflow of this invention is as follows: First, the three-jaw clamp 27 of the pipe clamp module precisely clamps the workpiece to be welded. The rotary motor 26 drives the three-jaw clamp 27 to rotate the workpiece at a uniform speed through the first transmission belt. The linear transmission module 21 of the multi-axis drive platform drives the moving frame 22 to move along the workpiece axis. The double-outlet hydraulic cylinder 23 synchronously adjusts the distance between the welding frame 2 and the inspection frame 3 to adapt to the workpiece size. The cooling spray pipe 4 is connected to the external water source through the metal corrugated pipe 24 and moves synchronously with the moving frame 22.

[0084] Next, the laser welding gun 5 on the welding frame 2 performs a ring welding operation on the rotating workpiece. The industrial camera 6 and infrared thermometer 7 arranged at 45° on both sides collect the initial shape and temperature data of the weld in real time and transmit them to the central control unit 25. The central control unit 25 adjusts the cooling water supply of the cooling nozzle 4 according to the temperature data, and performs precise spray cooling on the weld through the spray head. The cooling wastewater and welding slag fall into the sludge collection box 44 at the bottom of the base frame 1.

[0085] Subsequently, the reciprocating pressure module on the inspection frame 3 drives the first cam disk 32 to rotate through the servo motor 28, which drives the pressure frame 8 to achieve vertical amplitude vibration. At the same time, the transmission shaft 31 transmits power to the cam shaft 36 of the friction transmission module through the linkage bevel gear, driving the slide 9 to perform horizontal amplitude vibration. The high temperature resistant anti-stick leveling rubber wheel 13 on the slide 9 first contacts the weld, and assists in slag removal and leveling the weld surface through the clamping force. Then, the rotating brush shaft 10 cleans the weld with the help of the wire brush bristles 11. The clean hot air generated by the hot air blower 43 is sprayed out from the high pressure hot spray hole 12 through the pump heat pipe and the hot flow channel in the rotating brush shaft 10, softening the welding slag to improve the cleaning effect and avoid secondary cooling and cracking of the weld.

[0086] Finally, the three detection modules arrayed on the probe plate 14 contact the cleaned weld seam through the detection steel ball 19 at the end of the probe rod 15. The compression spring 18 and the limiting ring 17 ensure that the probe rod 15 is stably attached to the weld seam. The displacement sensor 16 transmits the detected displacement signal to the central control unit 25 to realize multi-point real-time detection of weld seam height and complete the integrated synchronous operation of welding, cooling, cleaning and detection.

[0087] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A shaft surface overlay welding seam height real-time detection device, comprising a base frame (1) on which a multi-axis drive platform is mounted, a welding frame (2) and a detection frame (3) are respectively connected on the multi-axis drive platform, characterized in that: a cooling nozzle (4) is further included and fixed on the multi-axis drive platform; a laser welding gun (5), an industrial camera (6) and an infrared temperature measuring instrument (7) are fixed on the welding frame (2); a pressure frame (8) is slidingly connected on the detection frame (3) and a reciprocating pressure module is fixed thereon, the reciprocating pressure module drives the pressure frame (8) to vertically oscillate, the pressure frame (8) is slidingly connected with a sliding frame (9), a friction transmission module for driving the sliding frame (9) to horizontally oscillate is arranged between the pressure frame (8) and the sliding frame (9), a rotating brush shaft (10) is drivingly connected on the friction transmission module, the rotating brush shaft (10) is rotationally connected on the sliding frame (9), steel wire bristles (11) are uniformly distributed on the top end of the rotating brush shaft (10), high-pressure hot spray holes (12) are arranged in an array, and a leveling rubber wheel (13) is rotationally arranged on the sliding frame (9); a probe plate (14) is fixed on the detection frame (3), and three detection modules are arranged in an array on the probe plate (14); the detection module comprises a probe rod (15) slidingly connected on the probe plate (14) and a displacement sensor (16) fixed on the probe plate (14), a monitoring end of the displacement sensor (16) faces the probe rod (15), a limiting ring (17) is fixed on the probe rod (15), a compression spring (18) is connected between the limiting ring (17) and the probe plate (14), and a detection steel ball (19) is embedded on the end of the probe rod (15); two symmetrical pipe clamp modules are further included, and a workpiece (20) to be welded is clamped on the two pipe clamp modules. The multi-axis drive platform comprises a linear transmission module (21) mounted on the base frame (1), a moving frame (22) is drivingly connected on the linear transmission module (21), the welding frame (2) and the detection frame (3) are slidingly connected with the moving frame (22), a double-rod hydraulic cylinder (23) is mounted on the moving frame (22), two movable ends of the double-rod hydraulic cylinder (23) are fixedly connected with the welding frame (2) and the moving frame (22) respectively, an axis of the double-rod hydraulic cylinder (23) is perpendicular to a transmission direction of the linear transmission module (21), and the cooling nozzle (4) is fixedly mounted on the moving frame (22).

2. The shaft surface overlay welding seam height real-time detection device according to claim 1, characterized in that, A plurality of spray heads facing the workpiece (20) to be welded are arranged in an array on the surface of the cooling nozzle (4), a metal corrugated pipe (24) is fixedly and communicatively connected on the cooling nozzle (4), a top-end-opened dirt receiving box (44) is mounted on the bottom of the base frame (1), a central control unit (25) is mounted on the end face of the base frame (1), and data ends of the industrial camera (6), the infrared temperature measuring instrument (7) and the displacement sensor (16) are in data connection with the central control unit (25).

3. The shaft surface overlay welding seam height real-time detection device according to claim 1, characterized in that, ​ 4. The shaft surface overlay welding seam height real-time detection device according to claim 1, characterized in that, The pipe clamp module comprises a rotary motor (26) fixedly installed on the base frame (1) and a three-jaw clamp (27) rotationally connected to the base frame (1), the three-jaw clamp (27) is used for clamping the workpiece (20) to be welded, and a first transmission belt is drivingly connected to an output shaft of the rotary motor (26), and the first transmission belt is drivingly connected to the three-jaw clamp (27).

5. The shaft surface overlay welding seam height real-time detection device according to claim 1, characterized in that, The reciprocating pressing module comprises a servo motor (28) installed on the detection frame (3), a vertical sliding table (29) slidingly connected to the detection frame (3), a first driven roller (30) rotationally connected to the pressing frame (8), and a transmission shaft (31), a first cam disc (32) is installed on an output shaft of the servo motor (28), four first protrusions (33) are arranged in the circumferential direction on the first cam disc (32), the four first protrusions (33) are alternately connected to the first driven roller (30), and the four first protrusions (33) have different transmission strokes for the first driven roller (30), the first pulley (34) is rotationally connected to the vertical sliding table (29), the vertical spring (35) is installed on the side surface of the vertical sliding table (29), the other end of the vertical spring (35) is fixedly connected to the detection frame (3), the second transmission belt is drivingly connected to the output shaft of the servo motor (28), and the first pulley (34) and the transmission shaft (31) are drivingly connected to the second transmission belt.

6. The shaft surface overlay welding seam height real-time detection device according to claim 2, characterized in that, The friction transmission module comprises a camshaft (36) rotationally connected to the pressing frame (8) and a second driven roller (37) rotationally connected to the sliding frame (9), the second cam disc (38) is installed on the camshaft (36), four second protrusions (39) are arranged in the circumferential direction on the second cam disc (38), the four second protrusions (39) are alternately connected to the second driven roller (37), and the four second protrusions (39) have different transmission strokes for the second driven roller (37), the linkage bevel gears are installed on the camshaft (36) and the transmission shaft (31), the two linkage bevel gears are orthogonally meshed, the horizontal sliding table (40) is slidingly connected to the pressing frame (8), the second pulley (41) is rotationally connected to the horizontal sliding table (40), the horizontal spring (42) is installed on the side surface of the horizontal sliding table (40), the other end of the horizontal spring (42) is fixedly connected to the pressing frame (8), the third transmission belt is drivingly connected to the camshaft (36), and the second pulley (41) and the rotary brush shaft (10) are drivingly connected to the third transmission belt.

7. The shaft surface overlay welding seam height real-time detection device according to claim 1, characterized in that, The device further comprises a hot air blower (43), a filter is installed on the air inlet port of the hot air blower (43), a heat pipe is communicated with the air outlet port of the hot air blower (43), a hot runner is formed in the rotary brush shaft (10), and the air outlet port of the heat pipe and the tail end of the high-pressure hot jet hole (12) are communicated with the hot runner.

8. The shaft surface overlay welding seam height real-time detection device according to claim 1, characterized in that, The industrial camera (6) and the infrared thermometer (7) are symmetrically arranged on both sides of the laser welding gun (5), the axis of the laser welding gun (5) and the rotating brush shaft (10) are perpendicular to the axis of the workpiece (20) to be welded, and the laser welding gun (5) is arranged directly above the workpiece (20) to be welded, the rotating brush shaft (10) is arranged directly below the workpiece (20) to be welded, and the included angle between the control end axis of the industrial camera (6) and the infrared thermometer (7) and the axis of the laser welding gun (5) is 45°.

9. The shaft surface overlay welding seam height real-time detection device according to claim 1, characterized in that, The axis of the leveling rubber wheel (13) is parallel to the axis of the workpiece (20) to be welded, the leveling rubber wheel (13) is made of high-temperature-resistant silicone rubber material, and a polytetrafluoroethylene anti-sticking coating is coated on the surface of the leveling rubber wheel (13).

Images