Automatic scanning equipment for internal defects of metal component based on eddy current principle

Abstract

The invention discloses metal component internal defect automatic scanning equipment based on the eddy current principle, and relates to the technical field of automatic scanning, the metal component internal defect automatic scanning equipment comprises a base, a detection assembly and a driving assembly are arranged on the side face of the base, and the detection assembly comprises an excitation coil and an elastic telescopic rod; the device has the advantages that the detection box is connected with the moving plate through the elastic telescopic rod, so that the elastic telescopic rod can adaptively adjust the longitudinal position of the detection box through the elastic deformation of the elastic telescopic rod when the surface of the component has tiny bulges, recesses or unevenness, and the optimal detection distance between the excitation coil and the surface of the component is always kept; a first servo motor drives a rotating frame to rotate, an exciting coil is driven by a sliding block to change an effective working area or turn number distribution, then transmission of eddy current signals with different frequencies is achieved, low-frequency signals can penetrate deeper, high-frequency signals are higher in resolution, and the frequencies can be flexibly switched according to the thickness of components and defect types.

Description

Technical Field

[0001] This invention relates to the field of automated inspection technology, specifically to an automated inspection device for internal defects in metal components based on the eddy current principle. Background Technology

[0002] In modern industrial systems, metal components are core basic components in aerospace, petrochemical, automobile manufacturing, power energy and other fields. Their internal integrity (such as whether there are defects such as cracks, inclusions, and porosity) directly determines the safety and service life of equipment operation. With the scaling up of industrial production, the increase in component complexity and the stringency of quality standards, traditional metal component defect detection technology has gradually revealed its limitations. Automated scanning equipment based on the eddy current principle has emerged to meet this need. Traditional equipment mostly uses single-frequency detection, which cannot flexibly adjust the signal frequency according to the thickness of the component and the type of defect, resulting in a high rate of missed detection of small and deep defects. To address this, we propose an automated inspection device for internal defects of metal components based on the eddy current principle. Summary of the Invention

[0003] The purpose of this invention is to provide an automated inspection device for internal defects in metal components based on the eddy current principle.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an automated inspection device for internal defects of metal components based on the eddy current principle, comprising a base, wherein a detection component and a driving component are provided on the side of the base; The detection assembly includes a movable plate, a detection box, an excitation coil, a rotating frame, a slider, and an elastic telescopic rod. The detection box and the movable plate are connected by the elastic telescopic rod. The side of the excitation coil is connected to the inner wall of the detection box. The side of the rotating frame is rotatably connected to the inner wall of the detection box. The slider is slidably connected to both the excitation coil and the side of the rotating frame. The drive assembly includes a support frame, a roller, a wheel, a bidirectional threaded rod, a movable frame, a drive shaft, and a connecting rod. The inner wall of the support frame is threadedly connected to the surface of the bidirectional threaded rod. The side of the roller is rotatably connected to the inner wall of the support frame. The side of the wheel is rotatably connected to the inner wall of the movable frame. The side of the drive shaft is slidably connected to the inner wall of the roller. The drive shaft and the movable frame are rotatably connected via the connecting rod.

[0005] As a further aspect of the present invention: a first servo motor is connected to the side of the detection box, and the output end of the first servo motor passes through the inner wall of the detection box and is connected to the center of the rotating frame.

[0006] As a further aspect of the present invention: a second servo motor is connected to the side of the support frame, and the output end of the second servo motor passes through the inner wall of the support frame and is connected to the side of the roller.

[0007] As a further aspect of the present invention: a third servo motor is connected to the side of the base, and the output end of the third servo motor passes through the inner wall of the base and is connected to one end of a bidirectional threaded rod.

[0008] As a further aspect of the present invention: a fixing frame is connected to the upper end face of the base, and a first electric telescopic rod is connected to the side of the fixing frame, wherein the telescopic end of the first electric telescopic rod is connected to the side of the movable plate.

[0009] As a further aspect of the present invention, the detection boxes are rotatably connected to each other.

[0010] As a further aspect of the present invention: a second electric telescopic rod is connected to the inner wall of the roller, and the telescopic end of the second electric telescopic rod is connected to one end of the drive shaft.

[0011] As a further aspect of the present invention: the side of the movable frame is slidably connected to the inner wall of the roller, and the side of the support frame is slidably connected to the side of the base.

[0012] As a further aspect of the present invention: the two ends of the bidirectional threaded rod are rotatably connected to the inner wall of the base.

[0013] Compared with the prior art, the beneficial effects of the present invention by adopting the above technical solution are as follows: 1. This invention connects the detection box and the moving plate via an elastic telescopic rod. When there are minor protrusions, depressions, or unevenness on the surface of the component, the elastic telescopic rod can adaptively adjust the longitudinal position of the detection box through its own elastic deformation to ensure that the excitation coil always maintains the optimal detection distance with the surface of the component, thus ensuring the stability of eddy current signal acquisition. The first servo motor drives the rotating frame to rotate, and the slider drives the excitation coil to change the effective working area or the number of turns distribution, thereby realizing the transmission of eddy current signals of different frequencies. Low-frequency signals can penetrate deeper, and high-frequency signals have higher resolution. The frequency can be flexibly switched according to the component thickness and defect type. 2. This invention uses rollers as a continuous conveying power source to realize assembly line operations of component loading, inspection, and unloading. With roller clamping and positioning, it can process tube, bar, and flat components in batches. It is suitable for large-scale quality inspection scenarios in industrial production and meets the needs of large-scale production. The core actions of the equipment are all automatically completed by servo motors and electric telescopic rods. Only manual loading and unloading of components are required, reducing the intensity of manual operation and avoiding problems such as detection position deviation and uneven force caused by manual operation, thus ensuring the consistency of detection results.

[0014] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of an embodiment of the present invention; Figure 2 This is a schematic diagram of a bidirectional threaded rod in an embodiment of the present invention; Figure 3 This is a schematic diagram of the roller in an embodiment of the present invention; Figure 4 This is a schematic diagram of the second electric telescopic rod in an embodiment of the present invention; Figure 5 This is a schematic diagram of the drive shaft in an embodiment of the present invention; Figure 6 This is a schematic diagram of the detection box in an embodiment of the present invention; Figure 7 This is a schematic diagram of the rotating frame in an embodiment of the present invention; Figure 8 This is a schematic diagram of the excitation coil in an embodiment of the present invention.

[0016] In the diagram: 1. Base; 2. Detection assembly; 21. Fixing frame; 22. First electric telescopic rod; 23. Moving plate; 24. Detection box; 25. First servo motor; 26. Excitation coil; 27. Rotating frame; 28. Slider; 29. ​​Elastic telescopic rod; 3. Drive assembly; 31. Support frame; 32. Second servo motor; 33. Roller; 34. Roller; 35. Third servo motor; 36. Bidirectional threaded rod; 37. Moving frame; 38. Second electric telescopic rod; 39. Drive shaft; 310. Connecting rod. Detailed Implementation

[0017] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. It should be noted that the description of these embodiments is for the purpose of helping to understand the present invention, but does not constitute a limitation of the present invention.

[0018] Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0019] Please see the appendix Figure 1 -Appendix Figure 8 The present invention is an automated inspection device for internal defects of metal components based on the eddy current principle, including a base 1, and a detection component 2 and a drive component 3 are arranged on the side of the base 1. In embodiment 1, the detection assembly 2 includes a movable plate 23, a detection box 24, an excitation coil 26, a rotating frame 27, a slider 28, and an elastic telescopic rod 29. The detection box 24 and the movable plate 23 are connected by the elastic telescopic rod 29. The side of the excitation coil 26 is connected to the inner wall of the detection box 24. The side of the rotating frame 27 is rotatably connected to the inner wall of the detection box 24. The slider 28 is slidably connected to the side of both the excitation coil 26 and the rotating frame 27. A first servo motor 25 is connected to the side of the detection box 24. The output end of the first servo motor 25 passes through the inner wall of the detection box 24 and is connected to the center of the rotating frame 27. A fixed frame 21 is connected to the upper end of the base 1. A first electric telescopic rod 22 is connected to the side of the fixed frame 21. The telescopic end of the first electric telescopic rod 22 is connected to the side of the movable plate 23. The detection boxes 24 are rotatably connected to each other. Specifically, the first servo motor 25 adopts a servo motor with a rated power of 100-200W, a speed adjustment range of 10-100r / min, and a positioning accuracy of ±0.1°. It can precisely control the rotation angle of the rotating frame 27 through pulse signals. The rotating frame 27 has a cross-shaped frame structure, and the slider 28 is embedded in the slide groove and fixedly connected to the lead end of the excitation coil 26. When the motor drives the rotating frame 27 to rotate 10°-90°, the slider 28 slides along the slide groove, causing the effective winding length of the excitation coil 26 to change (e.g., from 80% to 50% of the original winding length), thereby changing the coil inductance value and realizing continuous adjustment of the eddy current frequency from 10Hz (long winding, low frequency) to 15MHz (short winding, high frequency), adapting to the detection needs of components of different thicknesses (e.g., 2mm thin aluminum tube, 30mm thick carbon steel flange); Adjacent inspection boxes 24 are connected by a hinge-type rotating shaft (the shaft diameter is 6-8mm and the material is wear-resistant brass), which can achieve a rotation angle adjustment of ±30°. When inspecting cylindrical pipe fittings with a diameter of 50-200mm, 3-5 inspection boxes 24 can form a "ring inspection group" around the outer circle of the pipe fitting. Each inspection box 24 rotates with the curved surface of the pipe fitting to the fitting position, covering the circumference of the pipe fitting, with no blind spots (traditional single inspection boxes require multiple angle adjustments, which can easily miss defects on the side of the pipe fitting).

[0020] In embodiment two, the drive assembly 3 includes a support frame 31, a roller 33, a wheel 34, a bidirectional threaded rod 36, a movable frame 37, a drive shaft 39, and a connecting rod 310. The inner wall of the support frame 31 is threadedly connected to the surface of the bidirectional threaded rod 36. The side of the roller 33 is rotatably connected to the inner wall of the support frame 31. The side of the wheel 34 is rotatably connected to the inner wall of the movable frame 37. The side of the drive shaft 39 is slidably connected to the inner wall of the roller 33. The drive shaft 39 and the movable frame 37 are rotatably connected via the connecting rod 310. A second servo motor 32 is connected to the side of the support frame 31. The output end of motor 32 passes through the inner wall of support frame 31 and is connected to the side of roller 33. The side of base 1 is connected to a third servo motor 35. The output end of the third servo motor 35 passes through the inner wall of base 1 and is connected to one end of bidirectional threaded rod 36. The inner wall of roller 33 is connected to a second electric telescopic rod 38. The telescopic end of the second electric telescopic rod 38 is connected to one end of drive shaft 39. The side of moving frame 37 is slidably connected to the inner wall of roller 33. The side of support frame 31 is slidably connected to the side of base 1. The two ends of bidirectional threaded rod 36 are rotatably connected to the inner wall of base 1. Specifically, the second electric telescopic rod 38 has a stroke range of 10-30mm, a thrust of 50-100N, and a response time of ≤0.5s. The telescopic range can be controlled by PLC programming. When the oil pipe is placed on the drum 33, the second electric telescopic rod 38 extends, pushing the drive shaft 39 to move 5-10mm along the axis of the drum 33. The drive shaft 39 drives the moving frame 37 to slide along the groove on the inner wall of the drum 33 through the connecting rod 310 (30-50mm in length, which can rotate around the shaft), so that the roller 34 (20-30mm in diameter, with a rubber coating and a friction coefficient ≥0.8) moves towards the oil pipe until the clamping force reaches 20-30N, preventing the oil pipe from slipping during transportation. The roller 33 has a diameter of 50-80mm and a length of 100-200mm. The surface is textured with anti-slip patterns (depth 0.5-1mm). It is made of high-strength aluminum alloy. The second servo motor 32 (rated power 200-300W) drives the roller 33 to rotate at a speed of 10-50r / min. The speed can be adjusted by a frequency converter to keep the oil pipe conveying speed at 0.1-0.5m / min (to adapt to the signal acquisition requirements of different detection frequencies, such as reducing the conveying speed during high-frequency detection to ensure that the signal acquisition time of each detection point is ≥0.5s).

[0021] Working principle: First, after the excitation coil 26 is energized, it generates an alternating electromagnetic field. When this electromagnetic field approaches the metal component, a closed induced current (i.e., eddy current) will be induced inside the component. The distribution and intensity of the eddy current are directly related to the conductivity, permeability and internal integrity of the component. If there are defects such as cracks, inclusions or looseness inside the metal component, the conductivity and permeability of the defect area will change abruptly, causing the flow direction and density of the eddy current to become locally disordered. This disorder will in turn affect the electromagnetic field around the excitation coil 26, causing the impedance (resistance + reactance) of the coil to change. The excitation coil 26 in the detection component 2 senses its own impedance change in real time and converts it into an electrical signal. Subsequently, the electrical signal is amplified, filtered and analyzed by the signal processing module to determine whether there are defects inside the component, as well as the approximate location and size of the defects. The core function of detection component 2 is to ensure that the excitation coil 26 maintains the optimal detection distance with the component surface through position adjustment and coil attitude control, thereby achieving full-area scanning without blind spots. The specific action logic is as follows: The fixed frame 21 on the base 1 is connected to the first electric telescopic rod 22, and its telescopic end is connected to the moving plate 23. Through the extension and retraction of the first electric telescopic rod 22, the moving plate 23 and the detection box 24 connected thereto can be moved laterally (perpendicular to the component conveying direction) to adjust the lateral relative position of the detection box 24 and the component to adapt to components of different diameters. The detection box 24 and the moving plate 23 are connected by an elastic telescopic rod 29. When there are small protrusions or unevenness on the surface of the component, the elastic telescopic rod 29 can adaptively adjust the longitudinal position of the detection box 24 through its own elastic deformation to ensure that the excitation coil 26 is always close to the surface of the component (avoiding electromagnetic field attenuation and decreased detection sensitivity due to excessive distance, or coil wear due to excessive distance). The first servo motor 25 can drive the rotating frame 27 to rotate inside the detection box 24. When the rotating frame 27 rotates, it will drive the slider 28 to slide along its own trajectory. Since the slider 28 and the excitation coil 26 are slidably connected, the change in the position of the slider 28 will indirectly change the effective working area or coil turns distribution of the excitation coil 26. This structural design enables the excitation coil 26 to emit eddy current signals of different frequencies, thereby adapting to the detection needs of different metal components and defects of different depths, and providing a diverse eddy current detection signal basis for subsequent identification of internal metal defects. The detection boxes 24 are rotatably connected to each other. This design allows multiple detection boxes 24 to form a flexible connection structure. When detecting curved components (such as pipes or arc-shaped parts), the detection boxes 24 can rotate adaptively with the curved surface of the component, ensuring that the excitation coils 26 in each detection box 24 can fit against the surface of the component and avoid blind spots in the scanning of curved surfaces. The core function of drive component 3 is to transport metal components (such as tubes, bars, and plates) and ensure the stability of the components' posture during the inspection process by clamping and fixing them. The specific action logic is as follows: The output end of the second servo motor 32 on the side of the support frame 31 is connected to the side of the roller 33. When the motor starts, it drives the roller 33 to rotate. The roller 33 is the main power source for component conveying. When the component is placed on the roller 33, the rotation of the roller 33 can drive the component to move at a constant speed along the axial direction (conveyance direction), realizing continuous automated detection. The output end of the third servo motor 35 on the side of the base 1 is connected to one end of the bidirectional threaded rod 36. The two ends of the bidirectional threaded rod 36 are rotatably connected to the inner wall of the base 1, and the inner wall of the support frame 31 is threadedly connected to the surface of the bidirectional threaded rod 36. When the motor starts, it drives the bidirectional threaded rod 36 to rotate. Due to the thread direction design of the bidirectional threaded rod 36, it will drive the two support frames 31 to slide along the side of the base 1 for adjustment. The spacing of the two side support frames 31 is adapted to components of different diameters. The inner wall of the roller 33 is connected to the second electric telescopic rod 38, the telescopic end of which is connected to one end of the drive shaft 39. The drive shaft 39 and the moving frame 37 are rotatably connected through the connecting rod 310, and the moving frame 37 is slidably connected to the inner wall of the roller 33. When the second electric telescopic rod 38 extends or retracts, it will push the drive shaft 39 to move axially along the roller 33. The drive shaft 39 drives the moving frame 37 to slide radially along the roller 33 through the connecting rod 310, thereby adjusting the position of the roller 34 on the moving frame 37. When the roller 34 moves towards the component, it can clamp the component from the side to prevent the component from shifting or shaking during the conveying process, ensuring accurate detection position. At this point, the entire workflow is completed.

[0022] The terms "front," "back," "left," "right," "top," and "bottom" all refer to the figures in the accompanying drawings. Figure 1 Based on.

[0023] In the description of this invention, it should be understood that the terms "center", "longitudinal", "lateral", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of this invention.

[0024] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments.

[0025] For those skilled in the art, various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and these variations still fall within the protection scope of the present invention.

Claims

1. An automated scanning device for internal defects of metal components based on the eddy current principle, comprising a base (1), characterized in that: The side of the base (1) is provided with a detection assembly (2) and a driving assembly (3); The detection assembly (2) comprises a moving plate (23), a detection box (24), an excitation coil (26), a rotating frame (27), a sliding block (28) and an elastic telescopic rod (29), the detection box (24) and the moving plate (23) are connected through the elastic telescopic rod (29), the side of the excitation coil (26) is connected to the inner wall of the detection box (24), the side of the rotating frame (27) is rotationally connected to the inner wall of the detection box (24), and the sliding block (28) is slidably connected to the sides of the excitation coil (26) and the rotating frame (27). The driving assembly (3) comprises a support frame (31), a roller (33), a roller (34), a bidirectional threaded rod (36), a moving frame (37), a driving shaft (39) and a connecting rod (310), the inner wall of the support frame (31) is threadedly connected with the surface of the bidirectional threaded rod (36), the side of the roller (33) is rotationally connected with the inner wall of the support frame (31), the side of the roller (34) is rotationally connected with the inner wall of the moving frame (37), the side of the driving shaft (39) is slidably connected with the inner wall of the roller (33), and the driving shaft (39) and the moving frame (37) are rotationally connected through the connecting rod (310).

2. The automated eddy current based metal component internal defect scanning apparatus of claim 1, wherein: The side of the detection box (24) is connected with a first servo motor (25), and the output end of the first servo motor (25) penetrates the inner wall of the detection box (24) and is connected with the center of the rotating frame (27).

3. The automated eddy current based metal component internal defect scanning apparatus of claim 1, wherein: The side of the support frame (31) is connected with a second servo motor (32), and the output end of the second servo motor (32) penetrates the inner wall of the support frame (31) and is connected with the side of the roller (33).

4. The automated eddy current based metal component internal defect scanning apparatus of claim 1, wherein: The side of the base (1) is connected with a third servo motor (35), and the output end of the third servo motor (35) penetrates the inner wall of the base (1) and is connected with one end of the bidirectional threaded rod (36).

5. The automated eddy current based metal component internal defect scanning apparatus of claim 1, wherein: The upper end surface of the base (1) is connected with a fixing frame (21), the side of the fixing frame (21) is connected with a first electric telescopic rod (22), and the telescopic end of the first electric telescopic rod (22) is connected with the side of the moving plate (23).

6. The automated eddy current based metal component internal defect scanning apparatus of claim 1, wherein: The detection boxes (24) are rotationally connected with each other.

7. The automated, eddy current based, scan system for the internal inspection of metal components as defined in claim 1, wherein: The inner wall of the roller (33) is connected with a second electric telescopic rod (38), and the telescopic end of the second electric telescopic rod (38) is connected with one end of the driving shaft (39).

8. The automated eddy current based metal component internal defect scanning apparatus of claim 1, wherein: The side of the moving frame (37) is slidably connected with the inner wall of the roller (33), and the side of the support frame (31) is slidably connected with the side of the base (1).

9. The automated, eddy current based, metal component internal flaw scanning apparatus of claim 1 wherein: The two ends of the bidirectional threaded rod (36) are rotationally connected with the inner wall of the base (1).

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