Intelligent detection device for surface defects of structural member

Abstract

The invention discloses an intelligent detection device for surface defects of structural parts, and particularly relates to the field of surface defect detection devices.The intelligent detection device comprises a detection table, mounting bases are fixedly arranged on the two sides of the top of the detection table, and a main rotating clamp and an auxiliary rotating clamp are arranged on the two sides of the tops of the two mounting bases correspondingly to fix the structural parts; and rotating assemblies used for rotating the structural part are arranged at the centers of the tops of the two mounting bases, a top plate is fixedly arranged at the top of the detection table, and an industrial camera used for detecting the surface of the structural part is arranged at the bottom of the top plate. The main rotating clamp and the auxiliary rotating clamp are used for stably clamping a structural part, the rotating assembly is matched, pose adjustment of the structural part in multiple degrees of freedom is achieved, meanwhile, the adjusting mechanism is used for synchronously driving the industrial camera to automatically move, dead-corner-free comprehensive detection of the outer surface of the structural part is achieved, and through the design of the double mounting bases, the detection precision is improved. The uninterrupted continuous detection operation is realized, and the detection efficiency and the automation level are obviously improved.

Description

Technical Field

[0001] This invention relates to the field of surface defect detection devices, and more specifically to an intelligent detection device for surface defects of structural components. Background Technology

[0002] Structural components refer to various parts that, after hoisting, assembly, and installation in fields such as building construction or machinery manufacturing, form the framework of an engineering entity or equipment and are capable of bearing loads. Specifically, in the mechanical field, structural components are the basic parts that make up a mechanical system. They are combined through different connection methods to achieve specific functions such as support, transmission, and motion. However, during the manufacturing process, the surface of structural components is prone to defects and cracks due to processing. These surface defects may seem "minor," but they can impair performance and even cause safety accidents. For example, microcracks on the surface of structural components can lead to stress concentration under stress (such as tension, vibration, and fatigue loads), causing the cracks to propagate and eventually leading to brittle fracture or fatigue failure. Therefore, intelligent inspection devices are needed to inspect their surfaces. Existing inspection devices typically employ machine vision inspection technology, which uses machine vision to replace human eyes and brains for detection, measurement, analysis, judgment, and decision-making control. This intelligent measurement and control technology is an important means of mimicking human visual perception to achieve automated measurement and control, and can simultaneously meet multiple needs of smart factories for environmental perception and autonomous control.

[0003] For example, the prior art disclosure CN118937228A discloses an apparatus and method for automatically identifying surface defects in structural components. This invention improves the structural component placement device to adapt to structural components of various shapes, maintains the stability of the detection surface, improves measurement accuracy, and avoids human error. The data processing module can quickly identify defects, improving production efficiency. This method can automatically identify surface defects in structural components. This application also discloses a method for automatically identifying surface defects in structural components.

[0004] However, the existing technologies described above still have the following problems: when using industrial vision systems to inspect structural components on fixtures, the fixed contact points can obstruct the camera's field of view, creating blind spots in that area. These blind spots can cause defects to be missed, posing a potential risk to the final product quality; manually adjusting the position of structural components for inspection is very time-consuming, thus affecting inspection efficiency. Therefore, this invention provides an intelligent inspection device for surface defects in structural components with high inspection efficiency. Summary of the Invention

[0005] To overcome the aforementioned deficiencies of the prior art, this invention provides an intelligent detection device for surface defects of structural components. It employs a main rotating clamp and a secondary rotating clamp to securely hold the structural component, and in conjunction with a rotating assembly, enables positional adjustment of the structural component in multiple degrees of freedom. Simultaneously, an adjustment mechanism synchronously drives the automatic movement of an industrial camera, achieving comprehensive, blind-spot-free inspection of the structural component's outer surface. Furthermore, the dual mounting base design enables uninterrupted continuous inspection operations, significantly improving inspection efficiency and automation levels, thereby solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an intelligent detection device for surface defects of structural components, comprising a detection platform, mounting seats fixedly provided on both sides of the top of the detection platform, a main rotating clamp and a secondary rotating clamp respectively provided on the top sides of the two mounting seats to fix the structural component, a rotating component for rotating the structural component being provided at the top center of the two mounting seats, a top plate fixedly provided on the top of the detection platform, an industrial camera for detecting the surface of the structural component being provided at the bottom of the top plate, the industrial camera being fixed to the top plate through an adjustment mechanism, and a feeding mechanism being provided on the front and rear sides of the two mounting seats, the feeding mechanism comprising a sliding plate, and a roller conveyor fixedly provided on the top of each sliding plate.

[0007] In a preferred embodiment, the main rotating clamp includes a main lifting block, and a main electric push rod passes through each of the two main lifting blocks. A main clamping plate is fixedly provided at one end of the piston rod of the main electric push rod, and a first motor is provided at the rear end of each of the two main lifting blocks. The output shaft of the first motor is connected to the main electric push rod through a gear set to drive the main electric push rod to rotate.

[0008] In a preferred embodiment, each of the two main lifting blocks is provided with a drive cavity, and the first motor and gear set are both installed in the drive cavity.

[0009] In a preferred embodiment, the secondary rotary clamp includes secondary lifting blocks, and secondary electric push rods pass through both secondary lifting blocks. A secondary clamping plate is fixedly provided at one end of the piston rod of the secondary electric push rod.

[0010] In a preferred embodiment, a drive cylinder is fixedly provided at the bottom of both main lifting blocks and the bottom of both auxiliary lifting blocks. The drive cylinder is embedded in the mounting base and automatically adjusts the height of the main lifting blocks and auxiliary lifting blocks, thereby accommodating structural components of different sizes.

[0011] In a preferred embodiment, the rotating assembly includes a vacuum adsorption platform, the bottom of which is connected to a second motor. Each of the two mounting bases has a mounting hole at the center of its top for mounting the second motor. The second motor drives the vacuum adsorption platform to rotate, which facilitates automatic adjustment of the angle of the structural components.

[0012] In a preferred embodiment, the adjustment mechanism includes an X-axis linear module fixedly embedded in the bottom of the top plate, a Y-axis linear module one fixedly disposed at the bottom of the X-axis linear module, a connecting frame fixedly disposed at the bottom of the Y-axis linear module one, and an industrial camera installed inside the connecting frame. The X-axis linear module and the Y-axis linear module one cooperate to realize the automatic adjustment of the industrial camera, thereby improving the detection efficiency.

[0013] In a preferred embodiment, two symmetrically distributed fixed seats are fixed on both the front and rear sides of the top of the detection platform. A second Y-axis linear module is fixed on the top of each fixed seat. The slide plate is fixed on the top of the second Y-axis linear module. The slide plate can move automatically through the second Y-axis linear module, thereby improving the feeding and unloading speed.

[0014] The technical effects and advantages of this invention are as follows: 1. The main rotary clamp and the auxiliary rotary clamp are used to firmly hold the structural components, and the rotating components are used to adjust the position and posture of the structural components in multiple degrees of freedom. At the same time, the adjustment mechanism is used to drive the industrial camera to move automatically, so as to achieve comprehensive inspection of the outer surface of the structural components without blind spots. 2. The dual mounting base design allows for simultaneous inspection on one mounting base and loading / unloading operations on the other, thus enabling uninterrupted continuous inspection operations and significantly improving inspection efficiency and automation level. 3. By arranging multiple slides on the inspection table and automatically driving their movement with the help of the Y-axis linear module, the automatic loading and unloading of structural components is realized, thereby significantly improving the inspection efficiency. At the same time, a roller conveyor is used to correct the position of the structural components, so that they are aligned between the main clamping plate and the auxiliary clamping plate, which improves the stability of the inspection process. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the main rotating clamp and the auxiliary rotating clamp of the present invention; Figure 3 This is a sectional view of the mounting base of the present invention; Figure 4 This is a cross-sectional view of the main lifting block of the present invention; Figure 5 This is a cross-sectional view of the auxiliary lifting block of the present invention; Figure 6 This is a schematic diagram of the adjustment mechanism structure of the present invention; Figure 7 This is a schematic diagram of the feeding mechanism of the present invention; Figure 8 This is a top view of the overall structure of the present invention.

[0016] The attached diagram is labeled as follows: 1. Inspection table; 2. Mounting base; 3. Main rotating clamp; 31. Main lifting block; 32. Main electric push rod; 33. Main clamping plate; 34. First motor; 35. Gear set; 36. Drive cavity; 4. Secondary rotating clamp; 41. Secondary lifting block; 42. Secondary electric push rod; 43. Secondary clamping plate; 5. Rotating assembly; 51. Vacuum adsorption platform; 52. Second motor; 53. Mounting hole; 6. Top plate; 7. Industrial camera; 8. Adjustment mechanism; 81. X-axis linear module; 82. Y-axis linear module one; 83. Connecting frame; 9. Feeding mechanism; 91. Slide plate; 92. Roller conveyor; 10. Drive cylinder; 11. Fixed base; 12. Y-axis linear module two. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Refer to the instruction manual appendix Figures 1-8 The present invention provides an intelligent detection device for surface defects of structural components, including a detection table 1. The detection table 1 is fixedly provided with mounting bases 2 on both sides of the top. The two mounting bases 2 are respectively provided with a main rotating clamp 3 and a secondary rotating clamp 4 on the top sides to fix the structural components. The top center of the two mounting bases 2 is provided with a rotating component 5 for rotating the structural components.

[0019] The top of the inspection platform 1 is fixedly equipped with a top plate 6, and the bottom of the top plate 6 is equipped with an industrial camera 7 for inspecting the surface of the structural components. The industrial camera 7 is an imaging device specifically designed for industrial automation and machine vision applications. It converts the light signals of the physical scene into standardized digital images, providing high-quality data support for subsequent image preprocessing, feature extraction, pattern recognition, and decision control. Since this is existing technology, it will not be described in detail here. The industrial camera 7 is fixed to the top plate 6 through an adjustment mechanism 8. Feeding mechanisms 9 are provided on both the front and rear sides of the two mounting bases 2. The feeding mechanism 9 includes a slide plate 91, and a roller conveyor 92 is fixedly installed on the top of each slide plate 91. The roller conveyor 92 is based on the rolling principle. The powered roller conveyor drives the roller to rotate through a drive device. It uses the friction between the roller and the material to move the structural components forward to achieve continuous conveying. Since this is existing technology, it will not be described in detail here.

[0020] like Figures 1-4As shown, the main rotating clamp 3 includes a main lifting block 31, and a main electric push rod 32 passes through each of the two main lifting blocks 31. A main clamping plate 33 is fixedly provided at one end of the piston rod of the main electric push rod 32. A first motor 34 is provided at the rear end of each of the two main lifting blocks 31. The output shaft of the first motor 34 is connected to the main electric push rod 32 through a gear set 35 to drive the main electric push rod 32 to rotate. A drive cavity 36 is provided in each of the two main lifting blocks 31. The first motor 34 and the gear set 35 are both installed in the drive cavity 36.

[0021] like Figure 2 , Figure 3 and Figure 5 As shown, the auxiliary rotating clamp 4 includes an auxiliary lifting block 41. An auxiliary electric push rod 42 passes through each of the two auxiliary lifting blocks 41. An auxiliary clamping plate 43 is fixedly provided at one end of the piston rod of the auxiliary electric push rod 42. A drive cylinder 10 is fixedly provided at the bottom of the two main lifting blocks 31 and the bottom of the two auxiliary lifting blocks 41. The drive cylinder 10 is embedded in the mounting base 2.

[0022] like Figures 1-3 As shown, the rotating assembly 5 includes a vacuum adsorption platform 51, which is a precision fixture that uses vacuum negative pressure to fix and adsorb workpieces. The bottom of the vacuum adsorption platform 51 is connected to a second motor 52. The top center of each of the two mounting bases 2 is provided with mounting holes 53 for mounting the second motor 52. A vacuum generating device (vacuum pump or vacuum generator) connected to the vacuum adsorption platform 51 is installed in the detection table 1. The vacuum generating device quickly extracts the air in the sealed area through the vacuum channel inside the vacuum adsorption platform 51, so that the air pressure in the sealed space is much lower than the external atmospheric pressure. The atmospheric pressure is used to press the structural components tightly onto the platform surface. Since this is existing technology, it will not be described in detail here.

[0023] In actual operation, the slide plate 91, located in front of the mounting base 2, moves towards the mounting base 2, and the roller conveyor 92 mounted on it automatically transports the structural component to be inspected between the main clamping plate 33 and the auxiliary clamping plate 43. Subsequently, the main electric push rod 32 and the auxiliary electric push rod 42 drive the main clamping plate 33 and the auxiliary clamping plate 43 to move respectively, clamping and fixing the structural component. After clamping, the slide plate 91 automatically resets to its initial position. Next, the drive cylinder 10 moves, causing the main clamping plate 33, the auxiliary clamping plate 43, and the clamped structural component to rise as a whole. The industrial camera 7 then starts and automatically adjusts its shooting position with the help of the adjustment mechanism 8 to achieve full coverage image acquisition of the top surface of the structural component. Afterward, the first motor 34 on the main lifting block 31 drives the main electric push rod 32 to rotate through the gear set 35, thereby driving the structural component and the auxiliary clamping plate 43 to rotate, so that the industrial camera 7 can capture images of its front side, bottom side, and rear side in sequence. Subsequently, the structural component descends to the top of the vacuum adsorption platform 51. After the main clamping plate 33 and the auxiliary clamping plate 43 release the structural component, the second motor 52 drives the vacuum adsorption platform 51 and the structural component to rotate 90°. Then, the main clamping plate 33 and the auxiliary clamping plate 43 clamp the structural component again and lift it up. The industrial camera 7 takes pictures of the side of the structural component for inspection, thereby achieving comprehensive inspection of the outer surface of the structural component without blind spots. During the entire process, if the industrial camera 7 detects a defect on the surface of the structural component, the system will immediately send a signal to the control terminal for timely handling by the staff. After the inspection is completed, the slide plate 91 located behind the mounting base 2 moves forward and outputs the inspected structural component through the roller conveyor 92, completing the automatic unloading process. At the same time, the adjustment mechanism 8 is used to move the industrial camera 7 to the top of another mounting base 2 for inspection. The design of two mounting bases 2 to support the structural component enables continuous inspection and greatly improves the inspection efficiency of surface defects of the structural component.

[0024] like Figure 6 As shown, the adjustment mechanism 8 includes an X-axis linear module 81 fixedly embedded in the bottom of the top plate 6, a Y-axis linear module 82 fixedly disposed at the bottom of the X-axis linear module 81, a connecting frame 83 fixedly disposed at the bottom of the Y-axis linear module 82, and the industrial camera 7 is installed inside the connecting frame 83.

[0025] The X-axis linear module 81 can drive the Y-axis linear module 82 to move left and right, and the Y-axis linear module 82 can drive the connecting frame 83 to move back and forth. This can improve the detection range of the industrial camera 7, eliminate the need for manual operation, and greatly improve the efficiency of structural component inspection.

[0026] like Figure 7As shown, two symmetrically distributed mounting bases 11 are fixed on both the front and rear sides of the top of the testing platform 1. Each mounting base 11 has a Y-axis linear module 12 fixed on its top, and the slide plate 91 is fixed on the top of the Y-axis linear module 12. The Y-axis linear module 12 enables the slide plate 91 to move automatically, thereby improving the feeding and unloading speed.

[0027] The X-axis linear module 81, Y-axis linear module 1 82, and Y-axis linear module 2 12 mentioned above can all be ball screw type linear modules. Their working principle is as follows: the servo / stepper motor outputs rotational motion, the motor is connected to the ball screw through a coupling (rotating synchronously), the ball screw nut is fixed to the nut seat, the guide mechanism restricts the rotation of the nut seat, and the nut seat drives the load to move linearly along the linear guide. Since this is a well-known existing technology, it will not be described in detail here.

[0028] In actual use, a PLC controller can be installed on the testing table 1 to control the operation of the main electric push rod 32, the first motor 34, the auxiliary electric push rod 42, the vacuum adsorption platform 51, the second motor 52, the industrial camera 7, the X-axis linear module 81, the Y-axis linear module 1 82, the roller conveyor 92, the drive cylinder 10, and the Y-axis linear module 2 12. The PLC controller has an internal battery to provide power. Furthermore, to facilitate remote data transmission from the industrial camera 7, a wireless transmission module is integrated into the PLC controller for remote control. The main electric push rod 32, the auxiliary electric push rod 42, and the industrial camera 7 are powered by their own batteries. All push rods 42 are electric push rods with built-in encoders. The encoder (incremental or absolute) can convert the linear displacement of the push rod into a pulse signal through the transmission mechanism and feed it back to the PLC controller to achieve precise control of the extension and retraction. The first motor 34 and the second motor 52 can both be DC servo motors. They rely on closed-loop control to achieve ultra-high precision angle control. The core consists of the motor body, servo driver and encoder. When this type of motor is combined with feedback elements such as photoelectric encoders and Hall sensors, it can achieve pulse-level position closed-loop control with low repeatability error, thus meeting the positioning requirements of this device. The above technologies are all existing commonly used technologies and will not be described in detail here.

[0029] In conclusion, 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. An intelligent detection device for surface defects of structural components, comprising a detection table (1), characterized in that: The testing platform (1) is fixedly provided with mounting bases (2) on both sides of the top. The two mounting bases (2) are respectively provided with a main rotating clamp (3) and a secondary rotating clamp (4) on the top sides to fix the structural components. The two mounting bases (2) are provided with a rotating component (5) for rotating the structural components at the top center. The top of the testing platform (1) is fixedly provided with a top plate (6), and the bottom of the top plate (6) is provided with an industrial camera (7) for testing the surface of the structural component. The industrial camera (7) is fixed to the top plate (6) by an adjustment mechanism (8). Feeding mechanisms (9) are provided on both the front and rear sides of the two mounting bases (2). The feeding mechanism (9) includes a slide plate (91), and a roller conveyor (92) is fixedly provided on the top of each slide plate (91).

2. The intelligent detection device for surface defects of structural components according to claim 1, characterized in that: The main rotating clamp (3) includes a main lifting block (31), and a main electric push rod (32) runs through each of the two main lifting blocks (31). A main clamping plate (33) is fixedly provided at one end of the piston rod of the main electric push rod (32). A first motor (34) is provided at the rear end of each of the two main lifting blocks (31). The output shaft of the first motor (34) is connected to the main electric push rod (32) through a gear set (35) to drive the main electric push rod (32) to rotate.

3. The intelligent detection device for surface defects of structural components according to claim 2, characterized in that: Both main lifting blocks (31) are provided with drive chambers (36), and the first motor (34) and gear set (35) are installed in the drive chambers (36).

4. The intelligent detection device for surface defects of structural components according to claim 1, characterized in that: The auxiliary rotating clamp (4) includes an auxiliary lifting block (41), and an auxiliary electric push rod (42) runs through each of the two auxiliary lifting blocks (41). An auxiliary clamping plate (43) is fixedly provided at one end of the piston rod of the auxiliary electric push rod (42).

5. The intelligent detection device for surface defects of structural components according to claim 4, characterized in that: A drive cylinder (10) is fixedly installed at the bottom of both main lifting blocks (31) and the bottom of both auxiliary lifting blocks (41), and the drive cylinder (10) is embedded in the mounting base (2).

6. The intelligent detection device for surface defects of structural components according to claim 1, characterized in that: The rotating assembly (5) includes a vacuum adsorption platform (51), the bottom of which is connected to a second motor (52), and the top center of each of the two mounting bases (2) is provided with mounting holes (53) for mounting the second motor (52).

7. The intelligent detection device for surface defects of structural components according to claim 1, characterized in that: The adjustment mechanism (8) includes an X-axis linear module (81) fixedly embedded in the bottom of the top plate (6), a Y-axis linear module (82) fixedly provided at the bottom of the X-axis linear module (81), a connecting frame (83) fixedly provided at the bottom of the Y-axis linear module (82), and the industrial camera (7) installed inside the connecting frame (83).

8. The intelligent detection device for surface defects of structural components according to claim 1, characterized in that: The detection platform (1) has two symmetrically distributed fixed seats (11) fixed on the front and rear sides of the top. Each fixed seat (11) has a Y-axis linear module two (12) fixed on its top. The slide plate (91) is fixed on the top of the Y-axis linear module two (12).

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