Automatic detection equipment for three-way catalyst liner and working method of automatic detection equipment

Abstract

The invention discloses automatic detection equipment for a three-way catalyst liner and a working method of the automatic detection equipment. The automatic detection equipment comprises a rack, a detection platform, input and output conveying mechanisms, a detection sensor and a circulating pushing mechanism, wherein the input and output conveying mechanisms are located on the two sides of the platform, and the detection sensor and the circulating pushing mechanism are located above the platform. The circulating pushing mechanism is arranged above the conveying mechanism and the detection platform in a crossing mode and comprises at least two pushing plates, and wheel bodies capable of freely rotating are arranged on the pushing faces of the pushing plates. And the mechanism is configured to synchronously transfer the to-be-detected liner at the tail end of the input conveying mechanism to the center of the detection platform and transfer the detected liner on the platform to the starting end of the output conveying mechanism in a working cycle. According to the invention, stable and lossless transfer and accurate positioning of the liner are realized through a rolling pushing mode of the wheel body, efficient and continuous automatic detection is realized through a synchronous circulating pushing action, and the detection efficiency and the product consistency are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of automated testing technology for gaskets, and more specifically, to an automated testing device for three-way catalytic converter gaskets and its operating method. Background Technology

[0002] As a core component of automotive exhaust purification systems, the performance of the three-way catalytic converter directly affects whether pollutant emissions meet standards. Inside this component, a gasket made of ceramic or metal fiber materials is typically installed. This gasket not only secures and seals the catalyst carrier but also provides crucial thermal insulation, preventing overheating of the housing. It is a key internal component ensuring the long-term stable and efficient operation of the catalytic converter. Therefore, the quality of the gasket itself, including its geometric dimensions (such as thickness uniformity), surface condition (free from stains, cracks, and other defects), and weight, must undergo rigorous testing to ensure the assembly quality and reliability of the final product.

[0003] Currently, the quality inspection of three-way catalytic converter gaskets mainly relies on two methods: manual inspection and semi-automatic equipment inspection.

[0004] Manual inspection is inefficient, labor-intensive, and its results are easily influenced by the inspector's subjective experience, visual fatigue, and emotional state, leading to inconsistent judgment standards and making it difficult to guarantee product quality consistency. Furthermore, manual loading, unloading, and positioning increase the risk of accidental contamination or damage to the gaskets.

[0005] To address these issues, some semi-automatic testing equipment has emerged on the market. However, these devices typically have significant limitations. First, their automation level is limited, often only automating a single step (e.g., automatic thickness measurement). Manual intervention or assistance is still required in stages such as gasket conveying, precise positioning, and transfer between workstations, failing to form a complete automated workflow and resulting in limited efficiency improvements. Second, and more critically, existing equipment has technical shortcomings in the gasket conveying and positioning stages. Because three-way catalytic converter gaskets are relatively fragile and need to accommodate various sizes in automated production lines, achieving smooth, damage-free transfer during conveying and rapid, accurate positioning at the testing station has always been a technical challenge. Existing conveying or pushing mechanisms often use rigid contact, which can easily lead to scratches on the gasket surface, edge damage, or positional shifts due to friction or misalignment during the pushing process. This not only affects testing accuracy but may even cause product scrapping. Furthermore, the inevitable gap between the conveyor belt and the fixed testing platform can easily cause the gasket to jam, sink, or change posture during transition, further impacting the stability and reliability of the automated process.

[0006] In summary, existing methods and equipment for testing three-way catalytic converter gaskets still have significant shortcomings in terms of testing efficiency, consistency, automation level, and especially in achieving stable, accurate, and non-destructive automated transport and positioning of the gaskets. Therefore, the industry urgently needs a highly automated, efficient, and fully automatic testing device that can completely solve the problems of stability and accuracy of the gaskets during transport and positioning. Summary of the Invention

[0007] To overcome the above-mentioned defects of the prior art, embodiments of the present invention provide an automatic detection device for three-way catalytic converter liners and its working method.

[0008] To achieve the above objectives, the innovative aspects of this invention are as follows:

[0009] frame;

[0010] The testing area is located on the rack and contains a testing platform.

[0011] The input conveying mechanism and the output conveying mechanism are located on both sides of the detection platform, respectively, and are used to input the pad to be tested into the detection area and output the tested pad from the detection area. The input conveying mechanism and the detection platform form a first transition, and the detection platform and the output conveying mechanism form a second transition area.

[0012] The detection sensor is located above the detection area and is used to detect the pads located on the detection platform;

[0013] A circular push mechanism is positioned across the top of the input conveying mechanism, the detection platform, and the output conveying mechanism;

[0014] The cyclic pushing mechanism includes at least two push plates, and the push surfaces of the push plates are provided with freely rotatable wheels. The cyclic pushing mechanism is configured to synchronously transfer the pad to be tested located at the end of the input conveying mechanism to the center detection position of the detection platform via the first transition zone in one working cycle, and transfer the tested pad located on the detection platform to the beginning of the output conveying mechanism via the second transition zone.

[0015] Furthermore, the aforementioned cyclical push mechanism also includes:

[0016] A pair of side plates extending along the liner conveying direction are fixed across and above the input conveying mechanism, the detection platform, and the output conveying mechanism.

[0017] Two bases are synchronously movable on the side plate, and each base drives a push plate to rise and fall;

[0018] Among them, the first distance between the center of the input transmission mechanism and the center of the detection platform, the second distance between the center of the detection platform and the center of the output transmission mechanism, and the third distance between the two push plates are equal to each other.

[0019] Furthermore, each base is provided with a vertically arranged cylinder, the output end of the cylinder is set downward and connected to one end of the push plate; the end of the push plate away from the cylinder is formed with a pushing part for contacting and pushing the side of the pad, and a wheel is set on the pushing part.

[0020] Furthermore, transition structures are provided in the first transition zone and / or the second transition zone to ensure a smooth transition of the liner.

[0021] Furthermore, the transition structure includes a chamfered transition plate fixed to the frame, the upper surface of which is flush with the bearing surface of the adjacent conveying mechanism or testing platform.

[0022] Furthermore, the aforementioned transition structure also includes guide strips located on both sides of the chamfered transition plate, the guide strips being fixed to the frame and extending along the pushing direction.

[0023] Furthermore, a pair of adjustable limit plates are provided above the transmission start end of the above-mentioned input transmission mechanism, and an initial transmission channel with padding is formed between the two adjustable limit plates; the adjustable limit plates are adjustablely mounted on the frame through the cooperation of the strip hole provided on them and the adjusting nut.

[0024] Furthermore, the two bases move synchronously via a timing belt or linear module.

[0025] This invention provides a method for operating an automatic detection device, comprising the following continuous cyclic steps:

[0026] Step S1: The pad to be tested is conveyed to the end of the input conveying mechanism;

[0027] Step S2: The cyclic pushing mechanism drives its push plate to descend to the working position and moves a fixed distance towards the output conveying mechanism, so that the first push plate pushes the pad to be tested to the center of the testing platform through the first transition zone, while the second push plate pushes the pad already tested on the testing platform to the beginning of the output conveying mechanism through the second transition zone (B).

[0028] Step S3: The push plate rises and resets, and the cyclic pushing mechanism moves in the opposite direction for a fixed distance and resets.

[0029] Step S4: The detection sensor detects the pad located at the center of the detection platform;

[0030] Repeat steps S1 to S4.

[0031] The technical effects and advantages of this invention are as follows:

[0032] 1. Smooth and precise pushing process, effectively protecting the pad and ensuring positioning accuracy: This invention replaces traditional sliding friction pushing with rolling friction contact by setting freely rotating wheels on the pushing surface of the pusher plate. This structure can adapt to the position of the pad during pushing, significantly reducing frictional resistance and lateral offset force, thereby completely solving the problems of surface scratches, edge bumps, and positional deviation that easily occur during automated transfer of the pad. It ensures that the pad is pushed smoothly and straight to the center of the detection platform, providing a reliable guarantee for achieving high-precision detection.

[0033] 2. This invention achieves a highly efficient and continuous automated inspection cycle, significantly improving production efficiency: Through a unique cyclic pushing mechanism design and equidistant coordination between workstations and pusher plate spacing, the equipment can simultaneously complete the "loading-positioning" and "unloading" actions within one work cycle, seamlessly integrating with the inspection process. This constitutes a fully automated, uninterrupted inspection production line, overcoming the inefficiencies and slow cycle times of manual and semi-automatic equipment, greatly improving inspection efficiency and capacity, while ensuring product inspection consistency. Attached Figure Description

[0034] Figure 1 This is a top view of the invention.

[0035] Figure 2 This is a side view of the cyclic pushing mechanism of the present invention.

[0036] Figure 3 This is a structural diagram of the end of the adjustable limiting plate of the present invention connected to the conveying mechanism.

[0037] Figure 4 This is a structural diagram of the end face of the transition structure of the present invention.

[0038] Figure 5 This is a side view of the transition structure of the present invention.

[0039] In the picture:

[0040] 1. Frame; 2. Detection area; 21. Detection platform; 3. Input conveying mechanism; 31. Adjustable limit plate; 311. Strip hole; 32. Adjusting nut; 4. Output conveying mechanism; 5. Detection sensor; 6. Circulating push mechanism; 61. Side plate; 62. Base; 63. Push plate; 631. Wheel; 64. Cylinder; 7. Transition structure; 71. Chamfered transition plate; 72. Guide bar; A. First transition area; B. Second transition area. Detailed Implementation

[0041] 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.

[0042] First Embodiment: Overall Structure and Basic Working Principle of the Equipment

[0043] This embodiment provides the basic structure and core working cycle of an automatic detection device for three-way catalytic converter gaskets.

[0044] like Figure 1 As shown, the automatic detection equipment provided by the present invention mainly includes a frame 1, a detection area 2, an input conveying mechanism 3, an output conveying mechanism 4, a detection sensor 5, and a cyclic pushing mechanism 6.

[0045] The frame 1 serves as the supporting frame for the entire equipment. It is welded from high-strength profiles and provides a stable mounting base for other components.

[0046] The testing area 2 is located in the middle of the frame 1. Inside the testing area 2, there is a flat testing platform 21 for accurately supporting and positioning the pad 100 to be tested. The testing platform 21 is preferably a metal plate, and its levelness has been precisely calibrated.

[0047] The input conveyor 3 and the output conveyor 4 are located on the left and right sides of the inspection platform 21, respectively. The input conveyor 3 continuously transports the pads 100 to be inspected from the upstream process to the front of the inspection station; the output conveyor 4 transports the inspected pads 100 to the next process. In this embodiment, both the input conveyor 3 and the output conveyor 4 use a motor-driven belt conveyor. Importantly, a certain gap is left between the end of the input conveyor 3 and the inspection platform 21, forming a first transition zone A; similarly, a gap is also left between the inspection platform 21 and the beginning of the output conveyor 4, forming a second transition zone B. These three bearing surfaces (input conveyor belt surface, inspection platform surface, and output conveyor belt surface) are adjusted to the same horizontal level.

[0048] The detection sensor 5 is fixed to the center position directly above the detection area 2 by a mounting beam. Figure 1 As shown, the detection sensor 5 integrates multiple functional modules, including a laser thickness gauge for measuring the pad thickness, a CCD industrial camera for visual inspection of surface stains or defects, and a weighing module connected to the data processing system (which can be integrated under the platform or set up independently). The detection sensor 5 is used to perform multi-parameter comprehensive detection of the pad 100, which is stationary at the center of the detection platform 21.

[0049] The cyclic pushing mechanism 6 is the core component for achieving an automated testing process. For example... Figure 1 and Figure 2 As shown, this mechanism is mounted horizontally above the input conveying mechanism 3, the detection platform 21, and the output conveying mechanism 4. It mainly comprises a pair of parallel and fixed side plates 61, which are fixed to the frame 1 by columns. Two bases 62 engage with linear guides on the side plates 61 via sliders, allowing them to slide synchronously and precisely along the length of the side plates 61 (i.e., the liner conveying direction). Each base 62 is equipped with a vertically arranged cylinder 64, whose piston rod extends downwards.

[0050] The key innovation of the cyclic pushing mechanism 6 lies in the design of its pusher plate 63. For example... Figure 2 As shown, the upper end of the pusher plate 63 is connected to the end of the piston rod of the cylinder 64. The lower end of the pusher plate 63 extends to form a pushing section, which is used to contact the side of the liner 100. In particular, a plurality of freely rotatable wheels 631 (such as small roller bearings) are installed on the inner side of the pushing section (i.e., the side facing the liner). When the pusher plate 63 pushes the liner, the wheels 631 roll into contact with the side of the liner, greatly reducing frictional resistance and enabling adaptive adjustment to ensure a smooth and straight pushing process, effectively preventing the liner from jamming or shifting.

[0051] The working principle of the equipment is as follows:

[0052] After the equipment is started, it enters a continuous working cycle.

[0053] 1. Initial / Preparation Stage: such as Figure 1 As shown, the cyclic pushing mechanism 6 is in the reset state. The two push plates 63 are in a raised, suspended position driven by their respective cylinders 64. At this time, a pad 100a to be tested is accurately conveyed to its end (i.e., the entrance of the first transition zone A) by the input conveying mechanism 3 and stops. Simultaneously, the center of the testing platform 21 may hold a pad 100b that has been tested in the previous cycle (for the first cycle, the platform is empty).

[0054] 2. Synchronous Push and Transfer Stage: The control system issues a command. First, the two cylinders 64 operate simultaneously, driving the two push plates 63 to descend until their wheels 631 contact the sides of the corresponding pads (100a and 100b). Next, the drive system (e.g., a servo motor driving the two bases 62 via a synchronous belt) moves the two bases 62 and the push plates 63 synchronously to the right (output direction) by a fixed distance d. This distance d is equal to the distance from the center of the input conveying mechanism 3 to the center of the detection platform 21, and also equal to the distance from the center of the detection platform 21 to the center of the output conveying mechanism 4, and simultaneously equal to the distance between the centers of the two push plates 63.

[0055] During this movement, the pusher plate on the left side smoothly pushes the pad to be tested 100a across the first transition zone A and precisely delivers it to the center of the testing platform 21.

[0056] The pusher plate on the right side synchronously pushes the tested pad 100b on the testing platform 21 through the second transition zone B and sends it to the beginning of the output conveying mechanism 4.

[0057] 3. Reset and Inspection Phase: After being pushed into position, the two cylinders 64 drive the push plate 63 to rise and detach from the pad. Then, the drive system drives the two bases 62 to move synchronously to the left and in the opposite direction by a distance d, returning to the initial position. At the same time, the output conveying mechanism 4 starts, sending the pad 100b out of the device. The new pad 100a, located at the center of the inspection platform 21, remains stationary, and the inspection sensor 5 above it begins to work, performing multiple inspections on it, including thickness, surface visual inspection, and weight.

[0058] 4. Cyclic Phase: While the inspection is in progress, the input conveyor 3 has already transported the next pad to be inspected to the end for waiting. Once the current inspection is completed, the equipment automatically repeats steps 2-3 above, achieving uninterrupted automated inspection flow operation.

[0059] This embodiment lays the foundation for the core architecture of the present invention, clarifies the basic principle of "synchronous cyclic pushing of dual push plates", and introduces the key feature of "wheel drag reduction and stable pushing".

[0060] Second embodiment: Specific implementation of the transition structure

[0061] Based on the first embodiment, this embodiment focuses on describing several specific designs of the transition structure 7 to ensure a smooth transition of the liner when crossing the gap, in order to solve the problems of liner falling off, getting stuck, or running off-center that may exist in the first transition zone A and the second transition zone B.

[0062] like Figure 4 and Figure 5 As shown, the transition structure 7 is mounted on the frame 1, located in the first transition zone A and / or the second transition zone B. Its basic function is to fill the gaps and provide a continuous, smooth transition surface.

[0063] As a preferred embodiment, such as Figure 4 and Figure 5 As shown, the transition structure 7 includes a chamfered transition plate 71. This chamfered transition plate 71 is bolted to the frame 1, and its upper surface is precision machined to ensure strict flushness with the belt surface of the adjacent input conveyor 3, the platform surface of the detection platform 21, or the belt surface of the output conveyor 4, eliminating any steps. Its front end (towards the padding) is machined into a slope or a rounded chamfer (e.g., ...). Figure 5As shown), this allows the pad 100 to smoothly and without impact drive onto the transition plate, effectively preventing the leading edge of the pad from getting stuck or the bottom surface from scratching.

[0064] To further improve the guiding accuracy during the pushing process and prevent the pad from shifting laterally when crossing the transition zone, the transition structure 7 can be further optimized. For example... Figure 4 As shown, a pair of guide strips 72 are symmetrically arranged on both sides of the chamfered transition plate 71. The guide strips 72 are elongated metal or polymer material components, securely mounted on the frame 1 by brackets. The guide strips 72 extend along the pad pushing direction, and their inner surfaces are smooth or embedded with low-friction materials (such as nylon or polytetrafluoroethylene), maintaining a small gap with the sides of the pad 100. When the push plate 63 pushes the pad 100 through the transition zone, the guide strips 72 effectively constrain and guide the sides of the pad, ensuring its linear movement.

[0065] Furthermore, the implementation of transition structure 7 is not limited to the above-described "plate + strip" combination. In another simplified embodiment, a chamfered transition plate 71 can be provided only in the transition area without the guide strip 72, which can still achieve the basic smooth transition function. Alternatively, depending on actual needs, a single guide strip can be provided only on the side of the pad that is prone to deviation.

[0066] This embodiment clarifies how to achieve a "smooth transition" through a detailed structural description.

[0067] Third Embodiment: Details of Auxiliary Positioning Mechanism and Synchronous Drive

[0068] This embodiment further refines the auxiliary positioning function and the driving details of the core mechanism of the device to reflect the adjustability, adaptability and reliability of the device.

[0069] First, to ensure compatibility with pads of different widths, an adjustable limit mechanism is installed at the beginning of the input conveying mechanism 3. For example... Figure 3 As shown, a pair of adjustable limiting plates 31 are installed on the frame 1 above the beginning of the input conveying mechanism 3 (i.e., the conveyor belt). The two adjustable limiting plates 31 are parallel and opposite each other, and the width of the channel between them determines the initial posture of the pad 100 upon entry. Each adjustable limiting plate 31 has a transverse slot 311. During installation, an adjusting nut 32 is passed through the slot 311 and screwed into the corresponding threaded hole on the frame 1. When it is necessary to adjust the channel width to accommodate pads of different sizes, simply loosen the adjusting nut 32, slide the limiting plate 31 along the slot 311 to the desired position, and then tighten the nut. This structure is simple, reliable, and easy to adjust, providing a guarantee for the guidance and coarse positioning of the pad during the initial stage of conveying.

[0070] Secondly, regarding the synchronous movement of the two bases 62 in the cyclic pushing mechanism 6, there are several mature engineering implementation methods. Besides the servo motor-driven synchronous belt method mentioned in Embodiment 1, another preferred implementation is to use linear modules. Each base 62 can be mounted on an independent linear module slide, and the two linear modules are synchronously controlled by the same controller to achieve high-precision, same-speed, and same-direction movement. Whether using synchronous belt drive or linear module drive, it ensures that the two push plates 63 maintain a strictly fixed distance d and move synchronously, which is the basis for achieving precise coordinated "push and deliver" movements.

[0071] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0072] Secondly: The accompanying drawings of the embodiments disclosed in this invention only involve the structures involved in the embodiments disclosed in this invention. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other.

[0073] 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 automatic testing device for three-way catalytic converter gaskets, characterized in that: include: Rack (1); The detection area (2) is located on the frame (1), and a detection platform (21) is provided inside it; The input conveying mechanism (3) and the output conveying mechanism (4) are located on both sides of the detection platform (21) respectively, and are used to input the pad to be tested into the detection area (2) and output the tested pad from the detection area (2). A first transition area (A) is formed between the input conveying mechanism (3) and the detection platform (21), and a second transition area (B) is formed between the detection platform (21) and the output conveying mechanism (4). A detection sensor (5) is located above the detection area (2) and is used to detect the pad located on the detection platform (21); A circular push mechanism (6) is positioned across the top of the input conveying mechanism (3), the detection platform (21), and the output conveying mechanism (4); The cyclic pushing mechanism (6) includes at least two push plates (63), and the push plates (63) are provided with freely rotatable wheels (631) on their pushing surfaces. The cyclic pushing mechanism (6) is configured to synchronously transfer the pad to be tested located at the end of the input conveying mechanism (3) to the center detection position of the detection platform (21) via the first transition zone (A) in one working cycle, and transfer the tested pad located on the detection platform (21) to the beginning of the output conveying mechanism (4) via the second transition zone (B).

2. The automatic detection device for a three-way catalytic converter gasket according to claim 1, characterized in that: The cyclic pushing mechanism (6) also includes: A pair of side plates (61) extending along the liner conveying direction are fixed across the top of the input conveying mechanism (3), the detection platform (21) and the output conveying mechanism (4); Two bases (62) are synchronously movable on the side plate (61), and each base (62) drives one of the push plates (63) to rise and fall; The first distance between the center of the input transmission mechanism (3) and the center of the detection platform (21), the second distance between the center of the detection platform (21) and the center of the output transmission mechanism (4), and the third distance between the two push plates (63) are equal to each other.

3. The automatic detection device for a three-way catalytic converter liner according to claim 2, characterized in that: Each of the bases (62) is provided with a vertically arranged cylinder (64), the output end of the cylinder (64) is set downward and connected to one end of the push plate (63); the end of the push plate (63) away from the cylinder is formed with a pushing part for contacting and pushing the side of the pad, and the wheel (631) is provided on the pushing part.

4. The automatic detection device for a three-way catalytic converter gasket according to claim 1, characterized in that: A transition structure (7) is provided in the first transition zone (A) and / or the second transition zone (B) to ensure a smooth transition of the liner.

5. An automatic testing device for a three-way catalytic converter liner according to claim 4, characterized in that: The transition structure (7) includes a chamfered transition plate (71) fixed on the frame (1), the upper surface of which is flush with the bearing surface of the adjacent conveying mechanism or detection platform (21).

6. The automatic detection device for a three-way catalytic converter gasket according to claim 5, characterized in that: The transition structure (7) also includes guide strips (72) provided on both sides of the chamfered transition plate (71), the guide strips (72) being fixed on the frame (1) and extending along the pushing direction.

7. An automatic testing device for a three-way catalytic converter liner according to claim 1, characterized in that: The input conveying mechanism (3) has a pair of adjustable limiting plates (31) above the conveying start end, and an initial conveying channel with padding is formed between the two adjustable limiting plates (31); the adjustable limiting plates (31) are adjustablely mounted on the frame (1) through the cooperation of the strip hole (311) provided thereon and the adjusting nut (32).

8. An automatic testing device for a three-way catalytic converter liner according to claim 2, characterized in that: The two bases (62) move synchronously via a timing belt or a linear module.

9. The operating method of the automatic detection equipment as described in any one of claims 1 to 8, characterized in that, Includes the following continuous cyclic steps: Step S1: The pad to be tested is conveyed to the end of the input conveying mechanism (3); Step S2: The cyclic pushing mechanism (6) drives its push plate (63) to descend to the working position and moves a fixed distance toward the output conveying mechanism (4) at the same time, so that the first push plate pushes the pad to be tested through the first transition zone (A) to the center of the testing platform (21), and the second push plate pushes the pad that has been tested on the testing platform (21) through the second transition zone (B) to the beginning of the output conveying mechanism (4); Step S3: The push plate (63) rises and resets, and the cyclic pushing mechanism (6) moves in the opposite direction to reset the fixed distance; Step S4: The detection sensor (5) detects the pad located at the center of the detection platform (21); Repeat steps S1 to S4.

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