Balancing ring liquid leakage detection method and device

Abstract

The invention relates to a balance ring liquid leakage detection method and device, and relates to the technical field of sealing element detection, and the method comprises the steps: responding to a detection signal, and obtaining a product parameter and a saline water parameter; determining an adjusting angle according to product parameters and rotating shaft parameters; the required temperature is determined through saline parameters, and meanwhile the heating position is determined through product parameters; heating is conducted based on the heating position, the actual temperature corresponding to the heating position is synchronously collected, and heating is stopped until all the actual temperatures are not smaller than the required temperature; the inclination direction and the spraying position are determined according to the actual temperature and the heating position; determining rotation parameters by combining the product parameters and the adjustment angle; product inclination is controlled based on the inclination direction and the adjusting angle, a preset rotating shaft is controlled to rotate based on the rotating parameters, and detection liquid is sprayed synchronously based on the spraying position; collecting a product image, and judging whether the product is qualified or not according to the product image and the dyeing characteristics. The method has the effects of reducing the omission ratio and improving the detection efficiency.

Description

Technical Field

[0001] This invention relates to the field of sealing component testing technology, and in particular to a method and apparatus for detecting leakage in a balance ring. Background Technology

[0002] As core components in industrial equipment, automobiles and other fields, the sealing performance of seals directly determines the stability, safety and reliability of equipment operation. Therefore, accurate leakage detection of seals before they leave the factory is a key process to prevent potential quality problems and ensure the safety of end products.

[0003] When the washing machine impeller rotates at high speed, it needs to be equipped with a balance ring containing two saline chambers to counteract eccentric vibration. The saline chambers of the balance ring are sealed by ultrasonic welding after being injected with liquid. Currently, the sealing test at the seal is done manually. The staff manually flips the balance ring so that the saline chamber is facing down, and leaves it for a period of time until leakage marks appear. Then, it is flipped again and the salt stains and wet marks on the seal and the surface of the chamber are visually observed to determine whether it is qualified.

[0004] However, minute leaks are faint and difficult to identify accurately with the naked eye. Furthermore, manual flipping is cumbersome and requires time to settling, resulting in a high rate of missed detections and low detection efficiency. Summary of the Invention

[0005] To reduce the false negative rate and improve the detection efficiency, this invention provides a method and apparatus for detecting leakage in a balance ring.

[0006] In a first aspect, the present invention provides a method and apparatus for detecting leakage in a balance ring, which adopts the following technical solution: A method for detecting leakage in a balance ring, comprising: Step 1: In response to the detection signal, acquire product parameters and saline parameters; Step 2: Determine the adjustment angle based on the product parameters and the preset rotation axis parameters; Step 3: Determine the required temperature using the brine parameters, and simultaneously determine the heating location using the product parameters; Step 4: Heat based on the heating location, and simultaneously collect the actual temperature corresponding to the heating location until all actual temperatures are not lower than the required temperature, then stop heating; Step 5: Determine the tilting direction and spraying location based on the actual temperature and heating location; Step 6: Determine the rotation parameters based on the product parameters and adjustment angle; Step 7: Control the product tilt based on the tilt direction and adjustment angle, then control the preset rotation axis to rotate based on the rotation parameters, and simultaneously spray the test liquid based on the spray position; Step 8: Collect product images and determine whether the product is qualified based on the product images and preset dyeing characteristics.

[0007] By adopting the above technical solution, the driving force of leakage at minute leak points is enhanced through a combination of tilting and rotation. Combined with the spraying of detection liquid and staining feature recognition, the detection sensitivity of minute leak points is significantly improved, solving the problems of high false negative rate and low efficiency in traditional manual detection.

[0008] Optional methods for determining the adjustment angle include: Step 20: Read the rotation axis position, tilt axis length, and set the tilt range from the rotation axis parameters; Step 21: Read the virtual midpoint position from the product parameters; Step 22: Set a virtual adjustment angle within the set tilt range; Step 23: Based on the tilt axis length and the virtual adjustment angle, determine the vertical distance between the virtual midpoint position and the rotation axis position; Step 24: Filter the vertical distance with the largest value and define the corresponding virtual adjustment angle as the adjustment angle.

[0009] By adopting the above technical solution, the vertical distance corresponding to different virtual adjustment angles is calculated based on the rotation axis parameters and product parameters. The angle corresponding to the maximum vertical distance is selected as the adjustment angle, which can maximize the centrifugal force arm length of the brine and make the brine generate the strongest centrifugal driving force when rotating.

[0010] Optional methods for determining the tilt direction and spray location include: Step 50: Calculate the temperature difference based on the actual temperature and the required temperature; Step 51: Select the two values ​​with the largest temperature difference and define the corresponding heating positions as the spraying positions; Step 52: Determine the included angle of the spray position by combining the spray position and the position of the rotation axis; Step 53: Take the direction of the angle bisector of the angle between the spraying positions as the tilting direction.

[0011] By adopting the above technical solution, the two heating positions with the highest leakage risk are selected as spraying positions based on the temperature difference, and the angle bisector of their included angle is used as the tilt direction, so that the two sealing points can obtain the maximum centrifugal force at the same time.

[0012] Optionally, methods for determining rotation parameters include: Step 60: Read the leakage force threshold and injection volume from the product parameters, and read the brine density from the brine parameters; Step 61: Define the vertical distance with the largest value as the farthest distance; Step 62: Calculate the moment of inertia using the injection volume, brine density, and furthest distance; Step 63: Calculate the rotational speed based on the moment of inertia and the leakage force threshold, and use it as the rotational parameter.

[0013] By adopting the above technical solution, combining the injection volume, brine density and the farthest distance to calculate the moment of inertia, and then deriving the rotation speed based on the leakage force threshold, it is ensured that the centrifugal force generated by the rotation is not lower than the leakage force threshold, thereby driving the brine to seep out from the tiny leak point.

[0014] Optionally, the method for determining the rotation parameters also includes: Step 64: Read the leakage area threshold and leakage volume threshold from the product parameters; Step 65: Calculate the theoretical centrifugal force based on the moment of inertia and rotational speed; Step 66: Combine theoretical centrifugal force, leakage area threshold, and actual temperature to obtain the leakage rate; Step 67: Calculate and determine the baseline time based on the leakage volume threshold and leakage rate; Step 68: Correct the reference time based on the required temperature and use it as the rotation time; Step 69: Integrate the rotation speed and rotation time to obtain the rotation parameters.

[0015] By adopting the above technical solution, a reference time for calculating the leakage rate is introduced, and the rotation time is dynamically corrected based on the required temperature. This avoids the problems of insufficient or excessive detection, and minimizes the detection time and improves detection efficiency while ensuring that the leakage volume reaches the identification threshold.

[0016] Optional methods for determining the leakage rate include: Step 660: Read the initial brine viscosity and leakage coefficient from the product parameters; Step 661: Determine the viscosity of the heated brine based on the initial brine viscosity and the actual temperature; Step 662: Calculate the leakage pressure difference based on the theoretical centrifugal force and leakage area threshold; Step 663: The quotient of the product of the leakage pressure difference and the leakage coefficient and the viscosity of the heated brine is taken as the leakage rate.

[0017] By adopting the above technical solution and accurately calculating the leakage rate, a scientific basis is provided for determining the rotation time, transforming the detection process from experience-driven to data-driven, and further improving the accuracy of the detection method.

[0018] Optionally, methods for determining whether a product is qualified include: Step 80: Filter out the target areas that meet the staining characteristics and their corresponding area from the product image, and read the severe leakage threshold from the product parameters; Step 81: If the area of ​​the leak is less than the leakage area threshold, the product is deemed qualified and transferred for further processing. Step 820: If the area is between the leakage area threshold and the severe leakage threshold, it is determined to be a repair product. Calculate the leakage difference based on the area and the leakage area threshold. Step 821: Determine the flushing and welding parameters based on the leakage difference and the target area; Step 822: Repair the product based on the flushing and welding parameters, and repeat step 7 after repair; Step 83: If the area is larger than the severe leakage threshold, it is determined to be a scrap product and the product is transferred to the preset scrap box.

[0019] By adopting the above technical solution, based on the comparison results of regional area and threshold, the accurate sorting of qualified products, repaired products and scrapped products can be achieved. A targeted flushing and welding process is designed for repaired products, which effectively reduces the product scrap rate and reduces resource waste.

[0020] Optionally, after filtering out target regions that match the staining characteristics, the following can be included: Step 800: Determine the critical range based on the leakage area threshold and the preset judgment coefficient; Step 801: Obtain the average edge gradient value of the target region; Step 802: If the area is within the critical range and the average edge gradient value is not greater than the preset gradient threshold, it is determined to be a suspected product, and the irradiation parameters are determined by the average edge gradient value. Step 803: Emit ultraviolet light to the target area based on the irradiation parameters, and repeat the product image acquisition step.

[0021] By adopting the above technical solution, the degree of image blurring is quantified by the average edge gradient value, and the contrast of staining features is enhanced by dynamically adjusting the irradiation parameters. This solves the problem of high false judgment rate of critical products and further improves the accuracy of detection results.

[0022] Secondly, this application provides a balance ring leakage detection device, which adopts the following technical solution: A balance ring leakage detection device, controlled by any of the above-mentioned balance ring leakage detection methods, includes a liquid injection welding structure and a rotation detection structure. The rotation detection structure includes a rotating shaft for driving the product to rotate and an inclined shaft rotatably connected to the rotating shaft for driving the product to tilt along the rotating shaft. The rotating shaft is connected to an external rotating device. The inclined shaft has a mounting base for fixing the product. A camera component is provided above the mounting base to capture a surface image of the product.

[0023] By adopting the above technical solution, the rotation axis and tilt axis of the rotation detection structure are linked, which can accurately execute the tilting and rotation actions in the method, providing stable power conditions for leakage detection. The multi-view industrial camera ensures the comprehensiveness of product image acquisition and guarantees the accuracy of the visual inspection process.

[0024] Optionally, the liquid injection welding structure includes a liquid injection machine and a welding machine. The liquid injection machine has a liquid injection end that corresponds one-to-one with the number of liquid injection ports of the product. The liquid injection end of the liquid injection machine is provided with a liquid injection platform for placing the product. The output end of the welding machine is provided with a welding platform for placing the product. The welding platform can rotate to make the sealing of the product correspond to the position of the output end of the welding machine.

[0025] By adopting the above technical solution, the injection end of the injection machine corresponds one-to-one with the product injection port, realizing precise quantitative injection of brine. The rotatable design of the welding table ensures that all the seals of the balance ring are precisely connected with the output end of the welding machine, improving the sealing performance of the welded seals.

[0026] In summary, the present invention has at least one of the following beneficial technical effects: By combining tilting and rotation, the driving force for leakage at minute leak points is enhanced. Combined with spraying detection liquid and staining feature recognition, the detection sensitivity of minute leak points is significantly improved, solving the problems of high false negative rate and low efficiency in traditional manual detection. A reference time for calculating the leakage rate is introduced, and the rotation time is dynamically adjusted based on the required temperature to avoid under- or over-detection. While ensuring that the leakage volume reaches the identification threshold, the detection time is minimized and the detection efficiency is improved. The rotating and tilting axes of the rotating detection structure are linked, which can accurately execute the tilting and rotating actions in the method, providing stable power conditions for leakage detection. The multi-view industrial camera ensures the comprehensiveness of product image acquisition and guarantees the accuracy of the visual inspection process. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the liquid injection welding structure of this application; Figure 2 This is a simplified structural diagram of the rotation detection structure of this application; Figure 3 This is a flowchart of a method for detecting leakage in a balance ring according to this application.

[0028] The parts referred to by the numbers in the above attached figures are as follows: 1. Liquid injection and welding structure; 11. Liquid injection machine; 111. Liquid injection end; 12. Welding machine; 121. Output end; 13. Liquid injection platform; 14. Welding platform; 2. Rotation detection structure; 21. Rotation shaft; 22. Tilt shaft; 23. Mounting base; 24. Imaging component. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0030] This invention discloses a device for detecting leakage in a balance ring.

[0031] Reference Figure 1 and Figure 2 A balance ring leakage detection device includes a liquid injection welding structure 1 and a rotation detection structure 2.

[0032] The liquid injection welding structure 1 includes a liquid injection machine 11, a welding machine 12, a liquid injection platform 13, and a welding platform 14.

[0033] The liquid injection machine 11 has a number of liquid injection ends 111, the number of which corresponds to the number of liquid injection ports of the product. The liquid injection platform 13 is located below the liquid injection ends 111. The welding machine 12 is an ultrasonic welding machine 12, and the welding platform 14 is rotatably installed below the output end 121 of the welding machine 12.

[0034] The rotation detection structure 2 includes a rotation shaft 21, a tilting shaft 22, a mounting base 23, and an imaging component 24.

[0035] The rotating shaft 21 is connected to an external rotating device to rotate under the drive of the rotating device. The tilting shaft 22 is rotatably mounted above the rotating shaft 21. The mounting base 23 is fixedly mounted above the tilting shaft 22. The imaging assembly 24 consists of several industrial cameras, all of which are located above the tilting shaft 22.

[0036] Place the product on the injection platform 13, start the injection machine 11 to inject brine from the product's injection port, and then move the product with brine to the welding platform 14. The welding platform 14 rotates to align one of the product's injection ports with the output end 121 of the welding machine 12. Start the welding machine 12 to weld the injection port to form a seal. The welding platform 14 rotates again to align the other injection port of the product with the output end 121. Repeat the welding to complete the injection welding operation.

[0037] The welded product is moved to the mounting base 23 for fixation. The tilting shaft 22 is activated to tilt the product. The rotating shaft 21 is then controlled to rotate the product centrifugally. After rotation, a test liquid is sprayed onto the sealing area. Finally, an industrial camera is used to capture images of the product to analyze and determine whether it is qualified.

[0038] Based on the same inventive concept, embodiments of the present invention provide a method for detecting leakage in a balance ring.

[0039] Reference Figure 3 A method for detecting leakage in a balance ring includes the following steps: Step 1: In response to the detection signal, acquire product parameters and saline parameters.

[0040] The detection signal is a high-level electrical signal that triggers the start of the detection process after the balance ring has fully entered the detection station and its end face coincides with the positioning reference. The position of the balance ring is monitored in real time by an infrared sensor installed at the entrance of the detection station. When the infrared sensor indicates that the balance ring is fully in place, a detection signal is automatically output.

[0041] Product parameters refer to a set of preset parameters that are directly related to the structural design and sealing performance requirements of the balance ring. These parameters include virtual midpoint position, various leakage thresholds, initial brine viscosity, leakage coefficient, and injection volume. The system automatically retrieves the complete product parameters for the corresponding model by scanning the unique identification code on the product surface.

[0042] The brine parameters refer to the key physicochemical properties of the brine injected into the brine chamber of the balance ring. Specifically, these parameters include brine mass, brine concentration, and brine density. Multiple brine parameters corresponding to the product parameters of the balance ring are pre-stored in the system, and the system automatically matches and obtains them after reading the product parameters.

[0043] Step 2: Determine the adjustment angle based on the product parameters and the preset rotation axis parameters.

[0044] The rotation axis parameters refer to the inherent design and calibration parameters of the rotation axis 21, including parameters such as the position of the rotation axis, the length of the tilt axis, and the set tilt range. The staff calibrates the coordinates of the rotation axis using a laser tracker, determines the length of the tilt axis by combining the mechanical design parameters of the tilt axis 22, defines the set tilt range through process experiments, and stores all parameters in the system for direct reading during testing.

[0045] The adjustment angle refers to the specific angle at which the balance ring is tilted along the rotation axis 21 in order to maximize the centrifugal leakage force of the brine. The specific method for determining this angle will be described in detail in subsequent steps and will not be repeated here.

[0046] The method for determining the adjustment angle includes the following steps: Step 20: Read the rotation axis position, tilt axis length, and set the tilt range from the rotation axis parameters.

[0047] The position of the rotation axis refers to the specific coordinate position of the central axis of the rotation axis 21 in three-dimensional space. The rotation axis 21 is calibrated at multiple points using a laser tracker, and the three-dimensional coordinate data of the central axis is recorded. The calibration results are pre-stored in the system and read directly during testing.

[0048] The tilt axis length refers to the actual mechanical length of the tilt axis 22. The tilt axis length is obtained by multi-point calibration of the tilt axis 22 using a laser tracker and is pre-entered into the system for direct reading during testing.

[0049] The tilt range is defined as the range of angles that the tilt axis 22 is allowed to tilt along the rotation axis 21. The leakage efficiency of tiny leaks is tested at different tilt angles, while ensuring operational stability. The final tilt range is pre-entered into the system and read directly during testing.

[0050] Step 21: Read the virtual midpoint position from the product parameters.

[0051] The virtual midpoint position refers to the midpoint of the line connecting the two seals of the balance ring. The virtual midpoint position is calculated using the three-dimensional geometric center formula based on the seal positions in the product parameters and is pre-integrated into the product parameters for direct reading during testing.

[0052] Step 22: Set a virtual adjustment angle within the set tilt range.

[0053] Virtual adjustment angles refer to multiple candidate tilt angles set at fixed intervals within a set tilt range. These angles are automatically generated by the detection system, starting from the initial angle of the set tilt range and increasing sequentially at fixed intervals to the final angle to form a set of virtual adjustment angles.

[0054] The fixed interval is preset in the system by the staff; in this embodiment, 1° is used.

[0055] Step 23: Based on the tilt axis length and the virtual adjustment angle, determine the vertical distance between the virtual midpoint position and the rotation axis position.

[0056] Vertical distance refers to the spatial vertical distance from the virtual midpoint to the rotation axis, which is the lever arm length corresponding to the centrifugal force on the brine. It is automatically calculated based on the three-dimensional coordinates of the virtual midpoint and the three-dimensional coordinate equations of the rotation axis, using the formula for the vertical distance from the spatial geometric midpoint to the straight line. Each virtual adjustment angle corresponds to a vertical distance.

[0057] Step 24: Filter the vertical distance with the largest value and define the corresponding virtual adjustment angle as the adjustment angle.

[0058] Since the vertical distance directly determines the magnitude of the centrifugal force, screening the maximum value can ensure that the brine exerts the strongest directional pressure on the sealing point of the balance ring, thereby accelerating the leakage of brine and improving detection efficiency.

[0059] Step 3: Determine the required temperature using the brine parameters, and simultaneously determine the heating location using the product parameters.

[0060] The required temperature refers to the target heating temperature preset based on the brine concentration in order to reduce the viscosity of the brine and accelerate its leakage. The brine concentration is read from the brine parameters, and the corresponding required temperature is looked up in the temperature correspondence table. The temperature correspondence table is a data table that records different brine concentrations and their corresponding required temperatures. It is obtained by technicians through pre-testing and will not be described in detail here.

[0061] The heating position refers to the heating area corresponding to the sealing point of the balance ring, that is, the annular area with a preset width determined by the distance between the sealing point and the center of the balance ring as the radius. This ensures that the brine in the balance ring is heated evenly. The position coordinates of the sealing point and the center are read from the product parameters and calculated based on the annular topology region generation algorithm.

[0062] Step 4: Heat based on the heating location, and simultaneously collect the actual temperature corresponding to the heating location until all actual temperatures are not lower than the required temperature, then stop heating.

[0063] Actual temperature refers to the temperature value of each heating position collected in real time by temperature sensors. Thermistor sensors are evenly set at the heating positions, and temperature data is collected every second and transmitted to the system to obtain the actual temperature of each heating position.

[0064] All actual temperatures not being lower than the required temperature indicates that the brine in the balance ring has met the detection requirements, and heating can be stopped. All collected actual temperatures are continuously compared with the required temperature, and a heating stop signal is issued when no actual temperature is lower than the required temperature.

[0065] Step 5: Determine the tilting direction and spraying location based on the actual temperature and heating location.

[0066] The tilt direction refers to the direction in which the balance ring tilts along the rotation axis 21 with the tilt axis 22. The specific method for determining this will be described in detail in subsequent steps and will not be repeated here.

[0067] The spraying location refers to the specific area where the detection liquid is sprayed in a directional manner. The specific method for determining this location will be explained in detail in subsequent steps and will not be repeated here.

[0068] The method for determining the tilt direction and spraying location includes the following steps: Step 50: Calculate the temperature difference based on the actual temperature and the required temperature.

[0069] Temperature difference refers to the difference between the actual temperature and the required temperature of a single heating position. It is calculated in real time by the detection system. The difference between the actual temperature and the required temperature is calculated for each heating position, and each heating position corresponds to a temperature difference.

[0070] Step 51: Select the two values ​​with the largest temperature difference and define the corresponding heating positions as spraying positions.

[0071] Because the sealing area is ultrasonically welded, its material density is higher than other parts, and its thermal conductivity is relatively greater. After the same heating treatment, the temperature difference at the corresponding position is greater. The sealing area is also used as the target detection area for leakage, and the corresponding heating position is defined as the spraying position.

[0072] Step 52: Determine the spray position angle by combining the spray position and the position of the rotation axis.

[0073] The spray position angle refers to the angle formed by two spray positions along the circumference of the balance ring, with the rotation axis as the center. The angle is calculated by constructing vectors pointing from the intersection of the rotation axis and the end face of the balance ring as the center, with each vector pointing to one of the two spray positions.

[0074] Step 53: Take the direction of the angle bisector of the angle between the spraying positions as the tilting direction.

[0075] The tilt direction refers to the orientation that maximizes the centrifugal force at both sealing points after the balance ring is tilted, ensuring the optimal squeezing effect of the brine on the sealing points. It is calculated using the polar angle averaging method based on the two spraying positions and the angle between the spraying positions.

[0076] Step 6: Determine the rotation parameters based on the product parameters and adjustment angle.

[0077] Rotation parameters refer to the core technical parameters that control the operation of the rotating shaft 21, including rotation speed and rotation time. The specific determination method will be introduced in detail in subsequent steps and will not be repeated here.

[0078] The method for determining rotation parameters includes the following steps: Step 60: Read the leakage force threshold and injection volume from the product parameters, and read the brine density from the brine parameters.

[0079] The leakage force threshold refers to the minimum centrifugal force required to produce effective leakage at the balance ring seal. It is calibrated based on other product parameters through standard leakage sample tests and is pre-integrated into the product parameters for direct reading during testing.

[0080] The filling volume refers to the standard volume of saline solution poured into a single saline chamber of the balance ring. It is the design filling volume of the balance ring, which is clearly specified in the production process documents and pre-integrated into the product parameters, and can be directly read during testing.

[0081] The density of brine refers to the mass per unit volume of brine injected into the brine chamber. The actual density of brine is measured by a hydrometer and pre-integrated into the brine parameters, which are then read directly during testing.

[0082] Step 61: Define the vertical distance with the largest value as the farthest distance.

[0083] The furthest distance refers to the vertical distance with the largest value selected. Using this distance can maximize the inertia and centrifugal force when the brine rotates.

[0084] Step 62: Calculate the moment of inertia using the injection volume, brine density, and farthest distance.

[0085] Moment of inertia refers to the measure of inertia of brine when it rotates around axis 21. It is a core physical quantity that reflects the magnitude of the rotational inertia of brine. It is calculated by substituting the infusion volume, brine density, and maximum distance into the formula: J=ρVr 2 , where J is the moment of inertia, ρ is the density of the salt water, and r is the farthest distance.

[0086] Step 63: Calculate the rotational speed based on the moment of inertia and the leakage force threshold, and use it as the rotational parameter.

[0087] Rotational speed refers to the rotational speed of the rotating shaft 21. It is calculated by substituting the moment of inertia and the leakage force threshold into the formula, which is: n = 60 / 2π × (F0 / J). ½ Where n is the rotation speed, F0 is the leakage force threshold, and J is the rotational inertia. The rotation speed and the time preset by the staff are integrated as the rotation parameters.

[0088] The method for determining rotation parameters also includes the following steps: Step 64: Read the leakage area threshold and leakage volume threshold from the product parameters.

[0089] The leakage area threshold refers to the critical leakage area that distinguishes between qualified and unqualified products. It is the maximum leakage area allowed by the sealing performance of the balance ring. Based on the end-use performance requirements of the balance ring, the impact of different leakage areas on equipment operation is tested, and the maximum leakage area that does not affect use is defined as the leakage area threshold. This threshold is pre-integrated into the product parameters and read directly during testing.

[0090] The leakage volume threshold refers to the minimum leakage volume required to make the leak point identifiable. Reaching this threshold ensures that staining traces are clearly identifiable. It is calibrated through a colorimetric test of the detection liquid and pre-integrated into the product parameters for direct reading during testing.

[0091] Step 65: Calculate the theoretical centrifugal force based on the moment of inertia and rotational speed.

[0092] The theoretical centrifugal force refers to the centrifugal force on salt water calculated based on the moment of inertia and rotational speed. The calculation formula is: F=J(2πn / 60) 2 Where F is the theoretical centrifugal force, n is the rotational speed, and J is the moment of inertia.

[0093] Step 66: Combine theoretical centrifugal force, leakage area threshold, and actual temperature to obtain the leakage rate.

[0094] The leakage rate refers to the volume of brine that leaks from the seal per unit time. The specific method for determining this rate will be explained in detail in subsequent steps and will not be repeated here.

[0095] The method for determining the leakage rate includes the following steps: Step 660: Read the initial brine viscosity and leakage coefficient from the product parameters.

[0096] Initial brine viscosity refers to the dynamic viscosity of brine at room temperature. The dynamic viscosity of brine of corresponding concentration at room temperature is measured by a rotational viscometer and pre-integrated into the product parameters for direct reading during testing.

[0097] The leakage coefficient is a leakage characteristic coefficient related to the sealing material of the balance ring and the ultrasonic welding sealing structure, reflecting the ease of leakage at the leak point. Standard leakage samples with different sealing structures are prepared, and their leakage rates are tested under different leakage pressure differences and viscosities to determine the corresponding leakage coefficient of the product. This coefficient is pre-integrated into the product parameters and can be directly read during testing.

[0098] Step 661: Determine the viscosity of the heated brine based on the initial brine viscosity and the actual temperature.

[0099] The viscosity of heated brine refers to the dynamic viscosity of brine after heating to the actual temperature. It is calculated by substituting the initial brine viscosity and the actual temperature into the formula: μ=μ0(1-αT), where μ is the viscosity of heated brine, μ0 is the initial brine viscosity, α is the preset brine viscosity temperature coefficient, and T is the difference between the actual temperature and the room temperature.

[0100] Step 662: Calculate the leakage pressure difference based on the theoretical centrifugal force and the leakage area threshold.

[0101] Leakage pressure difference refers to the pressure generated by the theoretical centrifugal force acting on the leakage area. It is the pressure driving force that drives brine leakage. The leakage pressure difference is calculated by quotienting the theoretical centrifugal force with the leakage area threshold.

[0102] Step 663: The quotient of the product of the leakage pressure difference and the leakage coefficient and the viscosity of the heated brine is taken as the leakage rate.

[0103] The leakage rate is calculated by substituting the leakage pressure difference, leakage coefficient, and heated brine viscosity into the formula: Leakage rate = Leakage pressure difference × Leakage coefficient / Heated brine viscosity.

[0104] Step 67: Calculate and determine the baseline time based on the leakage volume threshold and leakage rate.

[0105] The reference time refers to the minimum rotation time required for the leakage volume to reach the leakage volume threshold, which is calculated by quotienting the leakage volume threshold and the leakage rate.

[0106] Step 68: Correct the reference time based on the required temperature and use it as the rotation time.

[0107] Rotation time refers to the actual rotation time obtained after correcting the reference time based on the required temperature. The correction rule is: for every 5°C increase in actual temperature from the required temperature, the reference time is shortened by 10%, and the corrected reference time is used as the rotation time.

[0108] Step 69: Integrate the rotation speed and rotation time to obtain the rotation parameters.

[0109] Replace the preset time with the rotation time and combine it with the rotation speed to obtain the rotation parameters.

[0110] Step 7: Control the product tilt based on the tilt direction and adjustment angle, and then control the preset rotation axis 21 to rotate based on the rotation parameters, while simultaneously spraying the test liquid based on the spray position.

[0111] The test solution is a neutral liquid that reacts quickly with salt water to produce a color change. It does not corrode the balance ring material. When sprayed at the spraying location, it will change color upon contact with the leaking salt water, making it easy to detect the extent of salt water leakage.

[0112] The tilting shaft 22 is controlled to rotate along the rotating shaft 21 based on the tilting direction and adjustment angle. Then, the rotating shaft 21 is controlled to rotate based on the rotation parameters to drive the balance ring to rotate synchronously. The brine in the balance ring continuously applies pressure to the sealing point under the action of centrifugal force to accelerate the leakage efficiency.

[0113] Step 8: Collect product images and determine whether the product is qualified based on the product images and preset dyeing characteristics.

[0114] The product image refers to a clear image of the ultrasonic welding sealing area of ​​the balance ring, which is obtained by taking pictures of the balance ring sealing area from directly above and at a 45° angle from both sides using an industrial camera.

[0115] The staining characteristics refer to the HSV color space parameter range of the characteristic color formed after the test solution reacts with saline. These characteristics are obtained through offline calibration using standard leak samples and are pre-stored in the system.

[0116] The method for determining whether a product is qualified includes the following steps: Step 80: Filter out the target areas that meet the staining characteristics and their corresponding area from the product image, and read the severe leakage threshold from the product parameters.

[0117] The target region refers to the set of pixels in the product image that meet the preset coloring features. The system calls the preset coloring feature HSV interval and performs binarization segmentation on the product image to obtain a partial region.

[0118] The area of ​​a region refers to the actual physical area corresponding to the target region. It is obtained by first calibrating the pixel equivalent, then counting the total number of pixels in the target region, and finally calculating the product of the two.

[0119] The severe leakage threshold refers to the critical leakage area that distinguishes repaired products from scrapped products. It is determined based on the repair process capability of the balance ring. By testing the repair effect of different leakage areas, the maximum leakage area that can meet the sealing requirements after repair is defined as the severe leakage threshold. This threshold is pre-integrated into the product parameters and read directly during testing.

[0120] After identifying the target regions that match the staining characteristics, the following steps are included: Step 800: Determine the critical range based on the leakage area threshold and the preset judgment coefficient.

[0121] The judgment coefficient is used to determine the area judgment range of suspected items. Its core function is to balance the detection accuracy and the false judgment rate. It is determined through multiple sets of process experiments, testing the accuracy and false judgment rate of suspected items under different coefficients, and selecting the coefficient with the best overall performance. It is then stored in the system in advance. In this embodiment, the judgment coefficient is 0.1.

[0122] The critical interval refers to the area range determined by the leakage area threshold and the judgment coefficient, which is calculated by the formula. The lower limit of the critical interval is (1 - judgment coefficient) × leakage area threshold, and the upper limit of the critical interval is (1 + judgment coefficient) × leakage area threshold.

[0123] Step 801: Obtain the average edge gradient value of the target region.

[0124] The average edge gradient value refers to the average gradient magnitude of the edge pixels of the target region. It is a core indicator for quantifying the edge sharpness of the target region. The edge contour of the target region is extracted by the Sobel operator, the gradient magnitude of each pixel is calculated, and then the average gradient magnitude of all edge pixels is calculated to obtain the average edge gradient value.

[0125] Step 802: If the area is within the critical range and the average edge gradient value is not greater than the preset gradient threshold, it is determined to be a suspected product, and the irradiation parameters are determined by the average edge gradient value.

[0126] If the area is within the critical range, it means that the area of ​​the target area falls within the critical range between qualified and repaired. If the average edge gradient value is not greater than the gradient threshold, it means that the edge of the staining trace is blurred. If both of the above conditions are met, it is judged as a suspected product.

[0127] Irradiation parameters refer to the intensity of ultraviolet irradiation, which is used to enhance the contrast of blurred staining features. The corresponding irradiation parameters are retrieved from the irradiation correspondence table based on the average edge gradient. The irradiation correspondence table is a data table that records different average edge gradients and their corresponding irradiation parameters. It is obtained by technicians through prior experimentation and will not be elaborated here.

[0128] Step 803: Emit ultraviolet light to the target area based on the irradiation parameters, and repeat the product image acquisition step.

[0129] Based on the irradiation parameters, ultraviolet light is emitted to the target area to enhance the contrast of blurred dyeing features, making the originally blurred leak marks clearly identifiable. The product image is then re-acquired and the product is judged to be qualified, i.e., step 8 is executed.

[0130] Step 81: If the area of ​​the leak is less than the leakage area threshold, the product is deemed qualified and transferred for further processing.

[0131] If the area of ​​the region is less than the leakage area threshold, it means that the actual leakage point area corresponding to the target area does not exceed the leakage area threshold, indicating that the sealing performance of the balance ring meets the usage requirements. The robotic arm is then used to grip the product and move it to the subsequent processing station.

[0132] Step 820: If the area is between the leakage area threshold and the severe leakage threshold, it is determined to be a repair product. The leakage difference is calculated based on the area and the leakage area threshold.

[0133] If the area is between the leakage area threshold and the severe leakage threshold, it means that the actual area of ​​the target area exceeds the leakage area threshold but does not exceed the severe leakage threshold, and repair can be carried out.

[0134] The leakage difference refers to the difference between the actual area of ​​the target area and the leakage area threshold, which is obtained by calculating the difference between the area and the leakage area threshold.

[0135] Step 821: Determine the flushing and welding parameters based on the leakage difference and the target area.

[0136] Flushing and welding parameters refer to the process parameters for targeted repair of the target area of ​​the repaired product. These include flushing pressure, ultrasonic welding parameters, and repair location. The corresponding flushing pressure and ultrasonic welding parameters are retrieved from the repair correspondence table based on the leakage difference. The repair correspondence table is a data table that records different leakage differences and their corresponding flushing pressure and ultrasonic welding parameters. It is obtained by technicians through prior testing and will not be elaborated here. The target area is taken as the repair location, and the flushing pressure, ultrasonic welding parameters, and repair location are integrated into the flushing and welding parameters.

[0137] Step 822: Repair the product based on the flushing and welding parameters, and repeat step 7 after repair.

[0138] The product is repaired using a pre-set welding equipment controlled by the flushing and welding parameters. After repair, step 7 is repeated to perform a second inspection of the product to ensure that the product's performance meets the standards.

[0139] Step 83: If the area is larger than the severe leakage threshold, it is determined to be a scrap product and the product is transferred to the preset scrap box.

[0140] The scrap bin is a storage box that is pre-installed near the rotation detection structure 2 and is used to store scrapped items.

[0141] If the area of ​​the area is greater than the severe leakage threshold, it means that the actual area of ​​the target area exceeds the severe leakage threshold, indicating that the leak point is too large and exceeds the limit of the repair process. It is directly judged as a scrap product, and the robotic arm is controlled to pick up the product and move it to the scrap bin for scrap recycling.

[0142] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for detecting leakage in a balance ring, characterized in that, include: Step 1: In response to the detection signal, acquire product parameters and saline parameters; Step 2: Determine the adjustment angle based on the product parameters and the preset rotation axis parameters; Step 3: Determine the required temperature using the brine parameters, and simultaneously determine the heating location using the product parameters; Step 4: Heat based on the heating location, and simultaneously collect the actual temperature corresponding to the heating location until all actual temperatures are not lower than the required temperature, then stop heating; Step 5: Determine the tilting direction and spraying location based on the actual temperature and heating location; Step 6: Determine the rotation parameters based on the product parameters and adjustment angle; Step 7: Control the product tilt based on the tilt direction and adjustment angle, and then control the preset rotation axis (21) to rotate based on the rotation parameters, and spray the test liquid simultaneously based on the spray position; Step 8: Collect product images and determine whether the product is qualified based on the product images and preset dyeing characteristics.

2. The method for detecting leakage in a balance ring according to claim 1, characterized in that, Methods for determining the adjustment angle include: Step 20: Read the rotation axis position, tilt axis length, and set the tilt range from the rotation axis parameters; Step 21: Read the virtual midpoint position from the product parameters; Step 22: Set a virtual adjustment angle within the set tilt range; Step 23: Based on the tilt axis length and the virtual adjustment angle, determine the vertical distance between the virtual midpoint position and the rotation axis position; Step 24: Filter the vertical distance with the largest value and define the corresponding virtual adjustment angle as the adjustment angle.

3. The method for detecting leakage in a balance ring according to claim 2, characterized in that, Methods for determining the tilt direction and spraying location include: Step 50: Calculate the temperature difference based on the actual temperature and the required temperature; Step 51: Select the two values ​​with the largest temperature difference and define the corresponding heating positions as the spraying positions; Step 52: Determine the included angle of the spray position by combining the spray position and the position of the rotation axis; Step 53: Take the direction of the angle bisector of the angle between the spraying positions as the tilting direction.

4. The method for detecting leakage in a balance ring according to claim 2, characterized in that, Methods for determining rotational parameters include: Step 60: Read the leakage force threshold and injection volume from the product parameters, and read the brine density from the brine parameters; Step 61: Define the vertical distance with the largest value as the farthest distance; Step 62: Calculate the moment of inertia using the injection volume, brine density, and furthest distance; Step 63: Calculate the rotational speed based on the moment of inertia and the leakage force threshold, and use it as the rotational parameter.

5. The method for detecting leakage in a balance ring according to claim 4, characterized in that, Methods for determining rotational parameters also include: Step 64: Read the leakage area threshold and leakage volume threshold from the product parameters; Step 65: Calculate the theoretical centrifugal force based on the moment of inertia and rotational speed; Step 66: Combine theoretical centrifugal force, leakage area threshold, and actual temperature to obtain the leakage rate; Step 67: Calculate and determine the baseline time based on the leakage volume threshold and leakage rate; Step 68: Correct the reference time based on the required temperature and use it as the rotation time; Step 69: Integrate the rotation speed and rotation time to obtain the rotation parameters.

6. The method for detecting leakage in a balance ring according to claim 5, characterized in that, Methods for determining the leakage rate include: Step 660: Read the initial brine viscosity and leakage coefficient from the product parameters; Step 661: Determine the viscosity of the heated brine based on the initial brine viscosity and the actual temperature; Step 662: Calculate the leakage pressure difference based on the theoretical centrifugal force and leakage area threshold; Step 663: The quotient of the product of the leakage pressure difference and the leakage coefficient and the viscosity of the heated brine is taken as the leakage rate.

7. The method for detecting leakage in a balance ring according to claim 5, characterized in that, Methods for determining whether a product is qualified include: Step 80: Filter out the target areas that meet the staining characteristics and their corresponding area from the product image, and read the severe leakage threshold from the product parameters; Step 81: If the area of ​​the leak is less than the leakage area threshold, the product is deemed qualified and transferred for further processing. Step 820: If the area is between the leakage area threshold and the severe leakage threshold, it is determined to be a repair product. Calculate the leakage difference based on the area and the leakage area threshold. Step 821: Determine the flushing and welding parameters based on the leakage difference and the target area; Step 822: Repair the product based on the flushing and welding parameters, and repeat step 7 after repair; Step 83: If the area is larger than the severe leakage threshold, it is determined to be a scrap product and the product is transferred to the preset scrap box.

8. The method for detecting leakage in a balance ring according to claim 7, characterized in that, After filtering out the target regions that match the staining characteristics, the following are included: Step 800: Determine the critical range based on the leakage area threshold and the preset judgment coefficient; Step 801: Obtain the average edge gradient value of the target region; Step 802: If the area is within the critical range and the average edge gradient value is not greater than the preset gradient threshold, it is determined to be a suspected product, and the irradiation parameters are determined by the average edge gradient value. Step 803: Emit ultraviolet light to the target area based on the irradiation parameters, and repeat the product image acquisition step.

9. A balance ring leakage detection device, employing a balance ring leakage detection method as described in any one of claims 1 to 8, comprising a liquid injection welding structure (1), characterized in that, It also includes a rotation detection structure (2); The rotation detection structure (2) includes a rotating shaft (21) for driving the product to rotate and an inclined shaft (22) rotatably connected to the rotating shaft (21) and for driving the product to tilt along the rotating shaft (21). The rotating shaft (21) is connected to an external rotating device. The inclined shaft (22) has a mounting base (23) for fixing the product. A shooting component (24) is provided above the mounting base (23) to capture a surface image of the product.

10. A balance ring leakage detection device according to claim 9, characterized in that, The liquid injection welding structure (1) includes a liquid injection machine (11) and a welding machine (12). The liquid injection machine (11) has a liquid injection end (111) that corresponds one-to-one with the number of liquid injection ports of the product. The liquid injection end (111) of the liquid injection machine (11) is provided with a liquid injection platform (13) for placing the product. The output end (121) of the welding machine (12) is provided with a welding platform (14) for placing the product. The welding platform (14) can rotate to drive the sealing of the product to correspond to the position of the output end (121) of the welding machine (12).

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