Cat1 intelligent water meter detection device

Abstract

The application discloses a Cat1 intelligent water meter detection device, which comprises a base, two groups of positioning seats with sealing plugs, a feeding drive module, an inflation module, an air pressure sensing module, a visual detection module and a rotating drive module. The device drives the sealing plugs on both sides to clamp and seal the water meter through the feeding drive module, and after being inflated by the inflation module, the rotating drive module is started synchronously in the pressure maintaining stage to drive the water meter to rotate, and the visual detection module which is fixedly arranged completes the whole circumference appearance image collection of the water meter. The application completes the appearance detection in parallel by using the pressure maintaining waiting time, integrates two processes efficiently in the same station, avoids secondary positioning and multi-camera layout, guarantees the detection precision, significantly improves the detection efficiency, simplifies the equipment structure and reduces the cost.

Description

Technical Field

[0001] This invention belongs to the field of water meter testing technology, specifically relating to a Cat1 smart water meter testing device. Background Technology

[0002] Before leaving the factory, Cat1 smart water meters undergo rigorous airtightness and visual inspection to ensure accurate metering, no leakage, and a flawless appearance. Traditional testing processes typically involve performing these two types of tests sequentially at different stations: first, at the airtightness testing station, the water meter is inflated and pressurized through a sealed joint to determine if there is a leak; then, it is transferred to the visual inspection station, where cameras capture images of various surfaces of the water meter and analyze for defects.

[0003] This serial, multi-station inspection method has significant drawbacks: First, it is inefficient. The "pressure holding" stage in airtightness testing often requires several to tens of seconds of stable observation time. During this period, the equipment and water meter are in a waiting state and cannot perform other effective operations, leading to a prolonged production cycle. Second, it suffers from low equipment integration, large footprint, and high cost. The two inspection systems are configured independently, requiring repetitive positioning, clamping, and transport mechanisms, increasing equipment complexity and production line footprint. Furthermore, to achieve full-circumference appearance inspection of the water meter, existing vision solutions typically require multiple cameras to simultaneously capture images from different angles, or rely on additional rotating mechanisms to drive the cameras around the water meter, further increasing system cost and control complexity.

[0004] Therefore, how to efficiently integrate airtightness testing and appearance inspection without affecting the accuracy and reliability of testing, so as to shorten the testing cycle, simplify the equipment structure and reduce production costs, has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution.

[0006] A Cat1 smart water meter testing device includes:

[0007] The base has a testing area in its center;

[0008] Two sets of positioning seats are arranged opposite each other and are respectively set on both sides of the detection area; each set of positioning seats is rotatably equipped with a top shaft assembly, and the top shaft assembly is provided with a sealing plug for sealing the water meter inlet and outlet at one end near the detection area;

[0009] The feed drive module is connected to one of the positioning seats and is used to drive the positioning seats to approach the other positioning seat in the horizontal direction to clamp the water meter placed between the two sealing plugs.

[0010] An inflation module, located on one of the sealed plugs, is used to fill the water meter with detection gas.

[0011] The air pressure sensing module is located on another sealed plug and is used to monitor changes in air pressure inside the water meter.

[0012] A visual inspection mechanism is located directly above the inspection area and is used to perform imaging inspection on the outer surface of the water meter when it is clamped.

[0013] A rotary drive mechanism is connected to one of the top shaft assemblies to drive the top shaft assembly and the water meter it holds to rotate synchronously, so as to achieve full-circumference appearance inspection.

[0014] In a preferred embodiment of a Cat1 smart water meter testing device, the top shaft assembly includes a coaxially assembled sleeve shaft and a fixed shaft. The fixed shaft is mounted inside the sleeve shaft via a bearing, and at least one sealing ring is provided between the sleeve shaft and the fixed shaft. One end of the fixed shaft protrudes from the end face of the corresponding sealing plug, and the other end is fixedly connected to a fixed frame fixed to the base, so that the fixed shaft remains stationary when the rotary drive mechanism drives the sleeve shaft to rotate. The inflation module and / or the air pressure sensing module are disposed at the end of the fixed shaft that extends to the end face of the sealing plug.

[0015] As a preferred embodiment of the Cat1 smart water meter testing device, the outer diameter of the sealing plug gradually increases axially from the end closest to the testing area.

[0016] As a preferred embodiment of a Cat1 smart water meter testing device, the sealing plug is provided with a plurality of sealing parts in sequence along the axial direction, and the sealing parts are adapted to the structure of water meters of different specifications.

[0017] As a preferred embodiment of a Cat1 smart water meter testing device, the sealing part is equipped with a sealing sleeve, the sealing sleeve having a first sealing surface located on the end face and a second sealing surface located on the circumferential surface.

[0018] The core effect of this technical solution lies in its innovative structural design, which enables parallel inspection of airtightness and visual appearance, thereby significantly improving overall inspection efficiency and equipment utilization. Specific technical effects are reflected in the following aspects:

[0019] 1. By integrating the inflation module and visual inspection mechanism into the same workstation, the originally idle pressure holding waiting time is fully utilized for appearance inspection, so that the two key inspection processes completely overlap in time, greatly improving inspection efficiency.

[0020] 2. By driving the water meter to rotate, only one fixed-installation vision inspection mechanism is needed to complete the panoramic appearance inspection of the water meter in all directions without blind spots. This avoids the need for multi-camera layout or complex motion mechanism, further simplifies the structure, reduces costs, and saves production line space.

[0021] 3. The sealing plug adopts a multi-stage conical sealing part design, which, together with the stroke adjustment of the feed drive module, can quickly adapt to water meters of different diameters and interface sizes, improving the versatility of the equipment and the flexibility of the production line. Attached Figure Description

[0022] Figure 1 This is a 3D view of the testing equipment.

[0023] Figure 2 This is a plan view of the testing equipment.

[0024] Figure 3 This is a 3D view of the testing equipment during testing.

[0025] Figure 4 A perspective view of a positioning seat equipped with an inflatable module.

[0026] Figure 5 This is a partial cross-sectional view of a sealing plug equipped with an inflation module.

[0027] The following is an explanation of the reference numerals in the attached figures:

[0028] 100. Base; 110. Testing area;

[0029] 200. Positioning and clamping mechanism; 210. Positioning seat; 220. Top shaft assembly; 221. Sleeve shaft; 222. Fixed shaft component; 223. Bearing; 224. Sealing ring; 225. Fixing frame; 226. Sealing plug; 226a. Sealing part; 227. Sealing sleeve; 230. Feed drive module;

[0030] 300. Inflation module; 301. Air inlet; 302. Air outlet; 303. Solenoid one-way valve; 310. Air pressure sensor module;

[0031] 400. Rotary drive mechanism;

[0032] 500. Visual inspection agency; 510. Industrial camera; 520. Ring light source;

[0033] 600. Water meter. Detailed Implementation

[0034] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0035] In the following embodiments, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0036] In the description of this invention, it should be understood that terms such as center, longitudinal, transverse, length, width, thickness, upper, lower, front, rear, left, right, vertical, horizontal, top, bottom, inner, outer, clockwise, counterclockwise, etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing and simplifying the description of this invention; therefore, they should not be construed as limiting this invention. Furthermore, terms such as first, second, etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features shown. In the description of this invention, unless otherwise expressly specified and limited, terms such as installation, connection, linking, etc., should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0037] Reference Figures 1 to 5 This embodiment provides a Cat1 smart water meter testing device that can simultaneously perform airtightness testing and full-circumferential visual inspection of a water meter 600 at the same workstation and under the same clamping condition, thereby significantly improving testing efficiency.

[0038] The testing equipment includes a base 100, a positioning and clamping mechanism 200, an inflation and air pressure testing system, a rotary drive mechanism 400, a vision inspection mechanism 500, and a central control system.

[0039] The base 100 serves as the support platform for the equipment. The central area of ​​the base 100 is defined as the detection area 110. This area is unobstructed, making it easy for the vision system to observe.

[0040] The positioning and clamping mechanism 200 is symmetrically arranged on both sides of the detection area 110, and is used to grasp, position, and clamp the water meter 600. This mechanism mainly includes two sets of opposing positioning seats 210 and a feed drive module 230. One set of positioning seats 210 is mounted on the base 100 via a linear guide pair and connected to the feed drive module 230, so as to drive the positioning seat 210 on this side to move closer to or away from the fixed or passively sliding positioning seat 210 on the other side, thereby realizing the clamping and releasing action. The feed drive module 230 is preferably a servo electric cylinder or a precision ball screw slide, used to provide precise and stable linear drive.

[0041] Each of the positioning seats 210 is rotatably mounted with a top shaft assembly 220, for reference. Figure 5The top shaft assembly 220 includes a coaxially assembled sleeve shaft 221 and a fixed shaft member 222. The sleeve shaft 221 is supported in the bearing 223 seat of the positioning seat 210 by a pair of angular contact ball bearings 223 and can rotate freely. The fixed shaft member 222 passes through the inner hole of the sleeve shaft 221 and forms a dynamic seal with the inner wall of the sleeve shaft 221 by at least one sealing ring 224. The tail end of the fixed shaft member 222 is rigidly connected to the base 100 by a fixing bracket 225, so that the fixed shaft member 222 always remains stationary regardless of how the sleeve shaft 221 rotates.

[0042] A sealing plug 226 is fixedly installed at the front end of the sleeve shaft 221. The sealing plug 226 is designed in the shape of a frustum cone, with its outer diameter gradually increasing from the front end to the rear end, forming a guide cone surface. At least two stages of sealing parts 226a of different diameters are distributed along its axial direction, and a sealing sleeve 227 can be fitted onto each stage of sealing part 226a. The sealing sleeve 227 is preferably made of elastic material, with its end forming a first sealing surface for axial sealing and its outer cylindrical surface forming a second sealing surface for radial sealing. This multi-stage, composite sealing structure can adapt to the depth and orifice of various water meter 600 interfaces of different specifications, and has strong versatility.

[0043] An inflation and pressure detection system is used to perform airtightness testing. This system includes an inflation module 300 and a pressure sensing module 310. In this embodiment, the inflation module 300 is used to supply and cut off the detection gas to the inner cavity of the water meter 600. It typically includes a gas source and an electromagnetic check valve 303 controlled by a central control system. The electromagnetic check valve 303 reliably cuts off the connection between the inflation gas path and the inner cavity of the water meter 600 after inflation stops, preventing gas backflow and ensuring that the pressure sensing module 310 can accurately monitor pressure changes in the closed cavity during the subsequent pressure holding phase. The inflation module 300 is connected to the air inlet 301 at the tail end of the left fixed shaft 222 via a pipeline. Gas flows out through the internal pipeline of the fixed shaft 222 from the air outlet 302 at the center of its front end face.

[0044] The air pressure sensing module 310 is installed at the tail end of the right-side fixed shaft 222, and its sensing end is connected to the front end face through the internal pipeline of the fixed shaft 222. Therefore, when the inlet and outlet of the water meter 600 are blocked by the sealing plugs 226 on both sides, a closed detection chamber is formed. The air inflation module 300 fills the chamber with clean air or nitrogen at a set pressure. After the inflation stops, it enters the pressure holding stage. The air pressure sensing module 310 monitors the decrease in air pressure in the chamber in real time to determine whether there is a leak in the water meter 600.

[0045] A rotary drive mechanism 400 is used to drive the water meter 600 to rotate during the pressure holding phase. This mechanism includes a servo motor and a reducer, which are connected to a sleeve shaft 221 on one side via a synchronous belt drive. When the motor starts, it drives the sleeve shaft 221, the sealing plug 226, and the clamped water meter 600 to rotate synchronously. Since both air filling and pressure measurement are performed via a stationary fixed shaft 222, the rotation of the water meter 600 does not cause any interference or risk to the air circuit connection or pressure measurement.

[0046] The visual inspection unit 500 is used to acquire images of the water meter 600's appearance. The system includes an industrial camera 510 fixedly mounted above the inspection area 110 and a matching ring light source 520. The ring light source 520 provides uniform illumination, and the optical axis of the industrial camera 510 points vertically downwards. When the rotary drive mechanism 400 drives the water meter 600 to rotate at a constant speed, the industrial camera 510 can continuously capture images at preset angular intervals or through external triggering, thereby acquiring a panoramic image sequence of the entire circumference of the water meter 600's outer surface, dial, glass cover, label, and other parts. These images are transmitted to the image processing unit of the central control system for defect analysis.

[0047] The central control system is responsible for coordinating the entire testing process: controlling the feed drive module 230 to complete clamping; controlling the inflation module 300 to complete inflation; during the pressure holding stage, simultaneously starting the rotary drive mechanism 400 and the vision inspection mechanism 500; receiving and processing the data from the air pressure sensor module 310 and the image from the industrial camera 510, and finally making a comprehensive judgment of pass / fail.

[0048] As a further optimization and extension of this embodiment, the testing equipment can be highly integrated into automated assembly lines or testing lines. Specifically, a working area for an industrial robotic arm can be planned and set up beside or above the testing area 110. This robotic arm is responsible for performing fully automated loading and unloading operations: grabbing the water meter 600 to be tested from the upstream conveyor line or silo and accurately placing it at the initial position of the testing area 110 of this equipment; after the testing cycle is completed, the water meter 600 is transported to different downstream flows (such as the qualified product packaging line or the unqualified product rework area) according to the sorting instructions (qualified / unqualified) issued by the central control system. Through this integration method, the entire process from handling, positioning, testing to sorting is automated without human intervention.

[0049] The working principle and testing process of this invention are as follows:

[0050] S1: Loading and clamping: Place the water meter 600 to be tested in the initial position of the testing area 110. The main control system starts the feed drive module 230, which drives the positioning seat 210 on the movable side to move towards the water meter 600 until the sealing plugs 226 on both sides are pressed into the inlet and outlet of the water meter 600, and a reliable seal is achieved through the sealing sleeve 227, thus completing the positioning and clamping.

[0051] S2: Inflation and Pressure Holding: The central control system controls the inflation module 300 to inflate the closed space formed by the inner cavity of the water meter 600 and the connecting pipeline with the preset pressure of detection gas. After the pressure is reached, the valve is closed and the pressure holding stage begins.

[0052] S3: Synchronous Rotation and Visual Inspection: At the start of the pressure holding stage, the central control system activates the rotation drive mechanism 400, driving the water meter 600 to rotate at a constant speed. Simultaneously, the visual inspection mechanism 500 is triggered, and the industrial camera 510 continuously captures circumferential images of the water meter 600 during its rotation.

[0053] S4: Data Acquisition and Judgment: During the pressure holding phase, the pressure sensor module 310 continuously records the pressure change value, and the visual image is transmitted and processed in real time.

[0054] S5: Unloading: The pressure holding stage ends, and rotation stops. The central control system combines the results of the air pressure drop rate and appearance defect detection to make a final judgment. Subsequently, the feed drive module 230 moves in the reverse direction, loosening the clamp on the water meter 600, allowing the water meter 600 to be removed, completing one detection cycle.

[0055] The beneficial effects of this invention are as follows: it perfectly integrates the rotation function with the static air path / detection path, thereby making full use of the time-consuming airtightness pressure holding waiting time for visual inspection. The two main inspection processes are changed from the traditional "serial" to "parallel" and no secondary positioning is required. While ensuring inspection accuracy, it significantly improves the overall inspection efficiency and reduces equipment complexity and cost.

[0056] The scope of protection of this invention includes, but is not limited to, the above embodiments. The scope of protection of this invention is defined by the claims. Any substitutions, modifications, or improvements to this technology that are easily conceived by those skilled in the art fall within the scope of protection of this invention.

Claims

1. A Cat1 smart water meter testing device, characterized in that, include: The base (100) has a detection area (110) in its middle section. Two sets of oppositely arranged positioning seats (210) are respectively arranged on both sides of the detection area (110); each set of positioning seats (210) is rotatably equipped with a top shaft assembly (220), and the top shaft assembly (220) is provided with a sealing plug (226) for sealing the inlet and outlet of the water meter (600) at one end near the detection area (110). The feed drive module (230) is connected to one of the positioning seats (210) and is used to drive the positioning seat (210) to approach the other positioning seat (210) in the horizontal direction to clamp the water meter (600) placed between the two sealing plugs (226). An inflation module (300) is disposed on one of the sealing plugs (226) for filling the water meter (600) with detection gas; A pressure sensing module (310) is mounted on another sealing plug (226) and is used to monitor changes in the internal pressure of the water meter (600); A visual inspection mechanism (500) is located directly above the inspection area (110) and is used to perform imaging inspection on the outer surface of the water meter (600) when it is clamped. A rotary drive mechanism (400) is connected to one of the top shaft assemblies (220) for driving the top shaft assembly (220) and the water meter (600) held therein to rotate synchronously, so as to achieve full-circumference appearance inspection; The top shaft assembly (220) includes a sleeve shaft (221) and a fixed shaft (222) coaxially assembled. The fixed shaft (222) is assembled inside the sleeve shaft (221) via a bearing (223), and at least one sealing ring (224) is provided between the sleeve shaft (221) and the fixed shaft (222). One end of the fixed shaft (222) protrudes from the end face of the corresponding sealing plug (226), and the other end is fixedly connected to the fixing frame (225) fixed to the base (100), so that when the rotation drive mechanism (400) drives the sleeve shaft (221) assembly to rotate, the fixed shaft (222) remains stationary. The inflation module (300) and / or the air pressure sensing module (310) are disposed at one end of the fixed shaft (222) extending to the end face of the sealing plug (226).

2. The Cat1 smart water meter testing device according to claim 1, characterized in that, The outer diameter of the sealing plug (226) gradually increases axially from the end closest to the detection area (110).

3. The Cat1 smart water meter testing device according to claim 2, characterized in that, The sealing plug (226) is provided with a plurality of sealing parts (226a) in sequence along the axial direction, and the sealing parts (226a) are adapted to the structure of water meters (600) of different specifications.

4. The Cat1 smart water meter testing device according to claim 3, characterized in that, A sealing sleeve (227) is fitted on the sealing part (226a), the sealing sleeve (227) having a first sealing surface located on the end face and a second sealing surface located on the circumferential surface.

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