Welding spot detection system and detection method

Abstract

The invention relates to a welding spot detection system and method, and relates to the technical field of welding spot detection. The connecting seat is arranged on the first side of the line moving box; the telescopic rod is fixedly connected between the line moving box and the connecting seat; the ultrasonic probe is arranged on the first side of the connecting seat; the spring seat is arranged on the first side of the connecting seat and connected with the connecting seat, the two ends of the spring are connected to the spring seat and the ultrasonic probe respectively, a pressure sensor is arranged in the spring seat, and the pressure sensor can detect the pressure of the spring; and the control module is coupled with the telescopic rod and the pressure sensor, and the control module can control the telescopic rod to stretch out and draw back according to a preset maximum pressure threshold value. The ultrasonic probe can be comprehensively and tightly attached to the target welding spot of the arc-shaped or special-shaped sheet metal part, the attaching gap caused by poor adaptability of a curved surface in a traditional technical scheme is eliminated, and the accuracy of detection data is guaranteed.

Description

Technical Field

[0001] This application relates to the field of solder joint inspection technology, and in particular to a solder joint inspection system and inspection method. Background Technology

[0002] Resistance spot welding is a core connection process in automobile manufacturing due to its low cost and ease of operation. During automobile body assembly, each vehicle's body structure requires thousands of weld points for connection and fixation. Furthermore, with the continuous expansion of market demand in the automotive industry, higher requirements are being placed on the efficiency and quality of weld point inspection.

[0003] Currently, there are two main methods for inspecting weld joints: traditional manual inspection and robot-assisted inspection. Traditional manual inspection requires manual completion of a series of operations, including weld joint calibration, visual inspection, manual recording of defects, and probe contact with the weld joint. This process is not only cumbersome but also inefficient. To address this issue, robot-assisted inspection has emerged, where a robot drives an ultrasonic sensor to achieve its lifting and positioning. However, this approach still has significant limitations: car bodies contain numerous curved and irregularly shaped sheet metal parts, and the weld joints on these parts are distributed on complex curved surfaces. The robot's movement trajectory is only adapted to flat or simple curved surfaces. This can lead to gaps in the contact between the ultrasonic sensor and the weld joints on curved or irregularly shaped sheet metal parts, as well as uneven force distribution. In such cases, manual assistance is needed to adjust the robot's posture or sensor angle. Furthermore, incomplete probe coverage of the weld joint can cause data distortion, resulting in the need for repeated inspections and a lack of improvement in inspection efficiency. Summary of the Invention

[0004] This application provides a weld joint detection system and method to solve the technical problem that the ultrasonic sensor is difficult to adapt to complex curved sheet metal parts when the robot drives the ultrasonic sensor for lifting and positioning, and the ultrasonic sensor probe is not able to completely cover the weld joint, resulting in distorted detection data, requiring repeated detection, and the detection efficiency still cannot be improved.

[0005] In a first aspect, this application provides a solder joint inspection system, comprising: Shift box; Connector, the connector is located on the first side of the transfer box; The telescopic pole is fixedly connected between the moving box and the connecting seat. An ultrasonic probe is positioned on the first side of the connector. A spring and a spring seat, the spring seat being disposed on the first side of the connecting seat and connected to the connecting seat, the two ends of the spring being respectively connected to the spring seat and the ultrasonic probe, and a pressure sensor being disposed inside the spring seat, the pressure sensor being capable of detecting the pressure of the spring; and The control module is coupled to the telescopic rod and the pressure sensor, and the control module can control the telescopic rod to extend or retract according to a preset maximum pressure threshold.

[0006] In one optional embodiment, the connector is provided with a connecting hole, the spring seat is configured as a hollow structure, and the spring seat is threadedly connected to the connecting hole of the connector.

[0007] In one alternative implementation, In one optional embodiment, a connecting flange is provided at one end of the telescopic rod near the connecting seat; The connecting seat is spaced apart from the connecting flange and connected by one or more bolts.

[0008] In one optional embodiment, the ultrasonic probe has a detection surface and one or more drainage holes disposed around the detection surface; and A coupling agent conduit, which passes through the connector, the spring seat, and the spring; The coupling agent conduit is coupled to the control module and communicates with the drain hole.

[0009] In an alternative embodiment, the ultrasonic probe further includes a chamfered surface disposed around the detection surface and inclined relative to the detection surface, and one or more drainage holes are spaced apart on the chamfered surface.

[0010] In an optional embodiment, the weld joint detection system further includes an image acquisition module, which includes one or more vision lenses disposed around the ultrasonic probe and fixedly connected to the connector. The image acquisition module is coupled to the control module.

[0011] In an optional implementation, the solder joint detection system further includes: Support frame, wherein a gun changing disc is provided on the support frame; and A drive mechanism is installed inside the support frame and connected to the moving box, and the drive mechanism is capable of driving the moving box to move.

[0012] In one alternative embodiment, the support frame includes: Multiple supporting legs; A first connecting frame is installed between the plurality of support legs for connecting the gun changing disc; The second connecting frame is installed between the plurality of support legs and is located on the first side of the first connecting frame for connecting the drive mechanism.

[0013] In an optional implementation, the drive mechanism includes: A first moving module, slidably connected to the second connecting frame and connected to the moving box, capable of driving the moving box to move along a first direction; and / or The second moving module is slidably connected to the second connecting frame and connected to the moving box, and can drive the moving box to move along the second direction.

[0014] Secondly, this application provides a solder joint detection method, implemented based on the aforementioned solder joint detection system, the solder joint detection method comprising: The control module establishes a coordinate system and imports the theoretical coordinates of the weld points and the corresponding qualified appearance images. Once the target solder joint is identified, the ultrasonic probe and image acquisition module are moved to a position above the target solder joint. The first image of the target solder joint is acquired using the image acquisition module. The first image is compared with the theoretical coordinates of the target solder joint and the appearance qualified image corresponding to the theoretical coordinates of the solder joint to determine the first detection result. The first detection result includes the appearance quality of the solder joint and the offset of the solder joint. If the appearance quality of the target solder joint is unqualified and / or the offset of the solder joint is greater than or equal to the first threshold, then the next target solder joint is detected. If the appearance quality of the target weld point is qualified and the offset of the weld point is less than the first threshold, the ultrasonic probe is moved to the actual position of the target weld point and ultrasonic testing is performed on the target weld point to obtain a second test result, which includes the welding quality of the weld point.

[0015] The technical solutions provided in this application have the following advantages compared with the prior art: The weld joint detection system provided in this application embodiment allows for adaptive rotation and fine-tuning of the ultrasonic probe around the contact portion of the target weld joint when the sheet metal part has a complex arc or irregular shape. This is achieved during the downward extension of the telescopic rod and the continuous compression of the spring, where the spring's elastic deformation causes the ultrasonic probe to rotate and fine-tune around the target weld joint until the ultrasonic probe is fully in contact with the surface of the target weld joint. The spring's adaptive elastic deformation enables the ultrasonic probe to achieve multi-directional rotational fine-tuning. Especially when dealing with arc or irregularly shaped sheet metal parts, the spring's flexible compensation allows the ultrasonic probe to form a comprehensive and tight fit with the target weld joint, eliminating the gaps caused by poor surface adaptability in traditional solutions and ensuring the accuracy of the detection data. Attached Figure Description

[0016] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0019] Figure 1 This is a schematic diagram of one embodiment of a weld joint detection system provided in this application. Figure 2 This embodiment provides a structural schematic diagram of one implementation of the support frame; Figure 3 This is a partial structural diagram provided in this embodiment; Figure 4 This is a partial structural schematic diagram from another perspective provided in this embodiment; Figure 5 This is a schematic diagram of the structure of the ultrasonic probe provided in this embodiment; Figure 6 This is a schematic diagram of the ultrasonic probe from another perspective provided in this embodiment; Figure 7 This is a cross-sectional view of the ultrasonic probe provided in this embodiment.

[0020] Explanation of reference numerals in the attached figures: 100. Moving box; 200. Connecting seat; 300. Telescopic rod; 310. Connecting flange; 400. Ultrasonic probe; 410. Drain hole; 420. Coupling agent conduit; 500. Spring; 600. Spring seat; 700. Image acquisition module; 710. Vision lens; 800. Support frame; 810. Gun changing plate; 820. Support leg; 821. Positioning pin; 830. First connecting frame; 840. Second connecting frame; 841. Connecting beam; 900. Drive mechanism; 910. First moving module; 911. First lead screw; 912. First fixed seat; 913. First motor; 914. First transmission rod; 920. Second moving module; 921. Second lead screw; 922. Second fixed seat; 923. Second motor; 924. Second transmission rod. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] The following disclosure provides numerous different embodiments or examples for implementing various structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. Additionally, examples of various specific processes and materials are provided in this invention; however, those skilled in the art will recognize the applicability of other processes and / or the use of other materials.

[0023] For ease of description, spatial relative terms may be used in the text to describe the relative position or movement of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "below," "above," "front," "back," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure. For example, if the device in the figure undergoes a positional flip, orientation change, or change of motion, these directional indications will change accordingly. For instance, an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The device may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in the text will be interpreted accordingly.

[0024] To address the technical challenges of robot-driven ultrasonic sensor positioning, where ultrasonic sensors struggle to adapt to complex curved sheet metal parts, resulting in incomplete coverage of weld points by the sensor probe, distorted detection data, and the need for repeated testing without improving efficiency, this application provides a weld point detection system and method. This system enables the ultrasonic probe to achieve a comprehensive and tight fit with the target weld points on curved and irregularly shaped sheet metal parts, eliminating the gaps caused by poor surface adaptability in traditional solutions and ensuring the accuracy of the detection data.

[0025] Figure 1 A solder joint inspection system provided in this application includes: 100-unit transfer box; Connector 200, the connector 200 is disposed on the first side of the transfer box 100; Telescopic rod 300 is fixedly connected between the moving box 100 and the connecting seat 200; An ultrasonic probe 400 is disposed on the first side of the connector 200. Spring 500 and spring seat 600. Spring seat 600 is located on the first side of connecting seat 200 and connected to connecting seat 200. The two ends of spring 500 are respectively connected to spring seat 600 and ultrasonic probe 400. A pressure sensor is installed inside spring seat 600. The pressure sensor can detect the pressure of spring 500. The control module is coupled to the telescopic rod 300 and the pressure sensor. The control module can control the telescopic rod 300 to extend or retract according to the preset maximum pressure threshold.

[0026] like Figures 1 to 4 As shown, the transfer box 100 can serve as a mounting base for other components, moving them to the target welding point. In this embodiment, the first side is defined as the bottom. The connecting seat 200 is located below the transfer box 100. The fixed end of the telescopic rod 300 is provided with a mounting flange, which has multiple mounting holes. Correspondingly, the transfer box 100 has threaded holes at corresponding positions. Screws pass through the mounting holes and are screwed into the threaded holes of the transfer box 100 to connect the telescopic rod 300 to the transfer box 100. The telescopic end of the telescopic rod 300 is connected to the connecting seat 200.

[0027] The spring seat 600 is connected to the end of the connecting seat 200 away from the telescopic rod 300. The spring seat 600 is provided with a first slot, and the ultrasonic probe 400 is provided with a second slot. One end of the spring 500 is engaged in the first slot, and the other end is engaged in the second slot, forming an elastic connection structure of the ultrasonic probe 400.

[0028] During weld point inspection, a robot connects to the inspection system and moves the system to the fixture at the inspection station of the sheet metal part to be inspected. The control module establishes a coordinate system using the fixture reference plate as a unified reference. After system initialization, the initial position of the ultrasonic probe 400 is first calibrated, and then the theoretical coordinates of each weld point to be inspected on the sheet metal part are imported into the control module. Initially, the telescopic rod 300 is in a retracted state. After determining the first target weld point, the moving box 100 moves each component to the target weld point position and continues to extend downwards. During the downward extension of the telescopic rod 300, the ultrasonic probe 400 first contacts the target weld point. At this time, the spring 500 is in a stretched state. Subsequently, the spring 500 is gradually compressed. During this process, the pressure sensor collects the pressure data of the spring 500 in real time. When the pressure value fed back by the pressure sensor reaches the preset maximum pressure threshold, the control module controls the telescopic rod 300 to stop extending immediately, indicating that the ultrasonic probe 400 has now come into contact with the surface of the target weld point. At this time, the ultrasonic probe 400 starts inspection, inspects the target weld point, and provides real-time feedback on the inspection results.

[0029] Among them, the theoretical coordinates of the solder joints are obtained from the product design data, which are the theoretical coordinates of all solder joints to be tested.

[0030] If the sheet metal part has a complex arc or irregular shape, during the process of the telescopic rod 300 extending downward and the spring 500 continuously compressing, the elastic deformation of the spring 500 will drive the ultrasonic probe 400 to perform adaptive rotation and fine adjustment around its contact part with the target weld point until the ultrasonic probe 400 is completely in contact with the surface of the target weld point.

[0031] The elastic adaptive deformation of spring 500 can drive ultrasonic probe 400 to achieve multi-directional rotational fine adjustment. Especially when facing curved or irregularly shaped sheet metal parts, the flexible compensation effect of spring 500 can make ultrasonic probe 400 form a full and tight fit with the target weld point, eliminating the fit gap caused by poor surface adaptability in traditional technical solutions, and ensuring the accuracy of test data.

[0032] The detection of the compression force of spring 500 serves two purposes: firstly, it acts as a buffer, preventing wear or deformation of the sheet metal caused by hard contact between the ultrasonic probe 400 and the sheet metal; secondly, it ensures a tight fit between the ultrasonic probe 400 and the target weld point through the stable pressure generated by continuous compression, thereby further improving the reliability of the detection results.

[0033] The ultrasonic probe 400 driven by the spring 500 has good self-adaptive capability, eliminating the need for frequent manual adjustment of its posture and complex trajectory algorithms in the control module. It can automatically fit the ultrasonic probe 400 with the weld points on curved and irregularly shaped sheet metal parts, effectively solving the technical problem of repeated adjustment of the ultrasonic probe 400 in traditional solutions. This can significantly shorten the detection time of a single weld point and improve detection efficiency.

[0034] Furthermore, in the technical solution of this embodiment, the robot only needs to perform simple actions of grasping, transferring and placing. The control logic and operation process are simple, and the requirements for robot degrees of freedom and positioning accuracy are low. It can be adapted to more conventional robot models, reducing the detection cost.

[0035] In some embodiments, the connector 200 is provided with a connecting hole, the spring seat 600 is configured as a hollow structure, and the spring seat 600 is threadedly connected to the connecting hole of the connector 200.

[0036] like Figure 3 and Figure 4 As shown, the spring seat 600 is cylindrical and hollow inside. An external thread is provided on its outer circumferential surface near the connecting seat 200, and an internal thread that mates with the external thread is provided in the connecting hole. During installation, the spring seat 600 is simply screwed onto the connecting seat 200. This detachable threaded connection design makes the assembly of the spring seat 600 more convenient and also facilitates the routine maintenance and replacement of subsequent components such as the spring 500 and the ultrasonic probe 400.

[0037] In some embodiments, a connecting flange 310 is provided at one end of the telescopic rod 300 near the connecting seat 200; The connecting seat 200 is spaced apart from the connecting flange 310 and connected by one or more bolts.

[0038] like Figure 3 and Figure 4 As shown, the connecting flange 310 has multiple connecting holes, and correspondingly, the connecting seat 200 also has multiple connecting holes at the corresponding positions. The connecting holes of the connecting seat 200 correspond one-to-one with the connecting holes on the connecting flange 310. Bolts pass through the two corresponding connecting holes and are fitted with nuts to securely connect the connecting flange 310 and the connecting seat 200.

[0039] In some embodiments, the ultrasonic probe 400 has a detection surface and one or more drain holes 410, the drain holes 410 being disposed around the detection surface in a weld joint detection system; and The coupling agent conduit 420 passes through the connector 200, the spring seat 600 and the spring 500; The coupling agent conduit 420 is coupled to the control module and communicates with the drain hole 410.

[0040] like Figures 4 to 7 As shown, multiple drainage holes 410 are preferably provided, and the multiple drainage holes 410 are equally spaced along the circumference of the detection surface. When the ultrasonic probe 400 is relatively close to the target welding point, the control module triggers the supply of coupling agent. The coupling agent is delivered to the drainage hole 410 through the coupling agent conduit 420, and a sufficient amount of coupling agent is discharged at one time, so that the coupling agent is evenly diffused along the edge of the detection surface to the entire detection surface, forming a continuous and uniform coupling agent layer, avoiding insufficient or missing coupling agent in some areas when the detection surface is in contact with the target welding point.

[0041] The couplant coating scheme provided in this embodiment avoids the problems of uncontrollable couplant dosage, insufficient or excessive couplant in traditional manual coating. It ensures stable transmission of ultrasonic signals, improves the reliability of detection data, saves couplant, and reduces detection costs. Multiple drainage holes 410 equidistantly arranged around the circumference of the detection surface ensure that the couplant is evenly discharged from all directions around the detection surface, quickly covering the detection surface and further guaranteeing the detection effect of weld joints on curved and irregularly shaped sheet metal parts.

[0042] Meanwhile, in the inspection of curved and irregularly shaped sheet metal parts, when the ultrasonic probe 400 is adjusted to fit the target weld point by the adaptive rotation of the spring 500, the coupling agent can further and evenly cover the detection surface during the rotation of the ultrasonic probe 400.

[0043] like Figures 4 to 7 As shown, the coupling agent supply end is located inside the moving box 100. One end of the coupling agent conduit 420 is connected to the coupling agent supply end, and the other end extends vertically downward, passing through the gap between the connecting seat 200 and the connecting flange 310. It then passes through the connecting seat 200, the spring seat 600, and the spring 500 in sequence, finally connecting with the end face of the ultrasonic probe 400 near the spring 500. It also connects with the drain hole 410 through the connecting hole inside the ultrasonic probe 400. The path of the coupling agent conduit 420 completely avoids the extension and retraction of the telescopic rod 300, the adaptive deformation of the spring 500, and the movement trajectory of the ultrasonic probe 400 during rotational fine-tuning. It also does not hinder the moving box 100 from driving the translation and positioning of each component, nor does it interfere with the attitude adjustment of the ultrasonic probe 400 during rotational fine-tuning. This ensures the independence and smoothness of the movement of each component, avoids the entanglement and pulling problems that may occur with the coupling agent conduit 420, ensures the smoothness of the entire detection process, and improves detection efficiency.

[0044] Furthermore, the top-down path allows the coupling agent conduit 420 to supply coupling agent more stably, reducing the likelihood of bending and poor coupling agent supply. The top-down design also aligns with the direction of gravity, further improving the coupling agent supply speed and reducing coupling agent retention and untimely supply issues.

[0045] Furthermore, with the detachable connection between the aforementioned connector 200 and spring seat 600, maintenance and replacement of the coupling agent conduit 420 only require disassembling the spring seat 600 and the coupling agent conduit 420 itself, making the maintenance process more convenient and simpler. In some embodiments, the ultrasonic probe 400 further includes a chamfered surface disposed around the detection surface and inclined relative to the detection surface, and one or more drain holes 410 are spaced apart on the chamfered surface.

[0046] like Figure 5 As shown, the chamfered surface extends upward from the probe surface and gradually tilts away from the probe surface. Thus, the height of the drain hole 410 is higher than the height of the probe surface. After the coupling agent is discharged from the drain hole 410, it flows downward naturally under the combined action of gravity and the chamfered surface until it reaches the probe surface. Furthermore, based on the tilting direction of the chamfered surface, the coupling agent will not diffuse outward from the probe surface after being discharged.

[0047] The chamfered surface can form directional guidance, reduce the random diffusion of the coupling agent, and enable the coupling agent to flow precisely to the core area of ​​the detection surface, so that the final coupling agent layer is sufficient and uniform.

[0048] In some embodiments, the weld joint detection system further includes an image acquisition module 700, which includes one or more vision lenses 710. The vision lenses 710 are disposed around the ultrasonic probe 400 and are fixedly connected to the connector 200. The image acquisition module 700 is coupled to the control module.

[0049] like Figures 3 to 4 As shown, in this embodiment, the image acquisition module 700 includes three vision lenses 710, which are equidistantly spaced along the circumference of the ultrasonic probe 400. The vision lenses 710 are fixed to the connecting base 200 and face downwards. Preferably, the lowest point of the vision lens 710 does not exceed half the length of the spring 500.

[0050] Three vision lenses 710 form a 360° all-around field of view, capturing image information of the target solder joint and its surrounding area from all directions, eliminating blind spots of a single lens. Especially for curved and irregularly shaped sheet metal parts, it can accurately identify the actual position and posture of the solder joint on complex curved surfaces. The lowest point of the vision lens 710 does not exceed half the length of the spring 500. This is to prevent the spring 500 from colliding with the lens when it deforms, ensuring accurate contact between the detection surface and the target solder joint without damaging the vision lens 710. On the other hand, it also prevents the vision lens 710 from directly colliding with the sheet metal part after the spring 500 deforms, protecting the vision lens 710 and reducing maintenance costs.

[0051] After the control module establishes the detection coordinate system and the system completes initialization, the theoretical coordinates of the solder joints and the corresponding appearance-qualified images are imported into the control module. Appearance-qualified images refer to actual photographs of solder joints that have passed inspection; these images are obtained based on historical records. An appearance-qualified image can be an actual photograph of a solder joint that has passed inspection and is located at the theoretical coordinates of the target solder joint, or it can be an actual photograph of a solder joint at other coordinates. In this embodiment, the appearance-qualified image is an actual photograph of a solder joint that has passed inspection and is located at the theoretical coordinates of the target solder joint; there is a one-to-one correspondence between the theoretical coordinates and the appearance-qualified images.

[0052] After the target solder joint is determined, the moving box 100 moves each component to above the theoretical coordinates of the target solder joint. The vision lens 710 starts and acquires images of the target solder joint area, capturing images of the target solder joint without blind spots, and transmits the acquired actual images to the control module.

[0053] The control module compares the acquired actual image with the theoretical coordinates of the target weld point and the appearance qualified image corresponding to the theoretical coordinates of the weld point.

[0054] Using the center of the approximate circle in the solder joint image as a comparison benchmark, the system automatically calculates the offset of the actual solder joint center relative to the theoretical solder joint center. If the offset is greater than or equal to 5mm, the solder joint is directly determined to be out of position and automatically discarded, without further ultrasonic testing. If the offset is less than 5mm, the control module corrects and determines the actual coordinates of the target solder joint, drives the moving box 100 to perform fine-tuning, and precisely corrects the ultrasonic probe 400 to the actual coordinates of the target solder joint, ensuring that the ultrasonic probe 400 is precisely aligned with the center of the target solder joint.

[0055] While performing position comparison, the control module also simultaneously compares the appearance of the actual weld point with the appearance of the theoretical weld point, automatically identifying and eliminating weld points with defects such as spatter, horseshoe-shaped points, and half-points. These weld points have irregular surface morphology and are not suitable for close contact detection with the ultrasonic probe 400, thus avoiding the problem of distorted detection results in subsequent detection processes.

[0056] For defective welds, the control module uploads the appearance quality judgment data and weld offset data of the defective welds to the visualization system in real time, and automatically stores and monitors the data in real time. The visualization system will immediately trigger an audible and visual alarm to remind the subsequent repair personnel to rework the defective welds. At the same time, it will also generate a traceable inspection record. The weld offset data will also be fed back to the control system of the welding robot, providing data support for the optimization and debugging of the welding parameters of the welding robot.

[0057] In some embodiments, the solder joint detection system further includes: Support frame 800, on which a gun changing plate 810 is installed; and The drive mechanism 900 is installed inside the support frame 800 and connected to the moving box 100. The drive mechanism 900 can drive the moving box 100 to move.

[0058] like Figures 1 to 2 As shown, the gun changing disc 810 is located on the upper part of the support frame 800 and is used to connect with the robot. The robot moves the entire weld point inspection system through the gun changing disc 810.

[0059] In some embodiments, the support frame 800 includes: Multiple support legs 820; The first connecting frame 830 is installed between multiple support legs 820 and is used to connect the gun changing plate 810. The second connecting frame 840 is installed between the plurality of support legs 820 and is located on the first side of the first connecting frame 830 for connecting the drive mechanism 900.

[0060] like Figures 1 to 2 As shown, the first connecting frame 830 is a rectangular frame with multiple reinforcing ribs inside to enhance its strength. Four support legs 820 are provided, each positioned at one of the four corners of the first connecting frame 830. Preferably, a positioning pin 821 is provided at the bottom of each support leg 820 to allow the support frame 800 to be installed on the inspection station of the sheet metal part to be inspected.

[0061] The second connecting frame 840 includes four connecting beams 841, which form a rectangular support structure. The two ends of each connecting beam 841 are respectively connected to two adjacent support legs 820.

[0062] The gun changing disc 810 and the support frame 800 can be made of aluminum alloy and can be welded together by argon arc welding to achieve a lightweight design.

[0063] In some embodiments, the drive mechanism 900 includes: A first moving module 910 is slidably connected to a second connecting frame 840 and connected to a moving box 100, capable of driving the moving box 100 to move along a first direction; and / or The second moving module 920 is slidably connected to the second connecting frame 840 and connected to the moving box 100, and can drive the moving box 100 to move along the second direction.

[0064] like Figures 1 to 2As shown, in this embodiment, both the first moving module 910 and the second moving module 920 are ball screw structures. The first moving module 910 includes a first screw 911, with a first fixed seat 912 at both ends of the first screw 911. A first motor 913 is mounted on one of the first fixed seats 912, and the output shaft of the first motor 913 is connected to the first screw 911 via a transmission. Two first transmission rods 914 are also provided between the two first fixed seats 912. These two first transmission rods 914 are parallel to the first screw 911 and are respectively located on both sides of the first screw 911. The two ends of the first transmission rods 914 are respectively mounted on two opposing connecting beams 841 (hereinafter referred to as the first connecting beams). Tracks are provided on the two first connecting beams, extending along the length of the first connecting beams. Rollers that cooperate with the tracks are provided at both ends of the first transmission rods 914.

[0065] Similarly, the second moving module 920 includes a second lead screw 921, with a second fixed seat 922 at both ends of the second lead screw 921. A second motor 923 is mounted on one of the second fixed seats 922, and the output shaft of the second motor 923 is connected to the second lead screw 921 for transmission. A second transmission rod 924 is also provided between the two second fixed seats 922. Two second transmission rods 924 are provided, parallel to the second lead screw 921 and respectively located on both sides of the second lead screw 921. The two ends of the second transmission rods 924 are respectively mounted on two opposing connecting beams 841, hereinafter referred to as the second connecting beams. Tracks are provided on the two second connecting beams, extending along the length of the second connecting beams. Rollers that cooperate with the tracks are provided at both ends of the second transmission rods 924.

[0066] The first lead screw 911 and the second lead screw 921 are arranged in a cross shape. Similarly, the first transmission rod 914 and the second transmission rod 924 are also arranged in a cross shape. The moving box 100 has through holes through which the first lead screw 911, the first transmission rod 914, the second lead screw 921 and the second transmission rod 924 pass. The through holes through which the first lead screw 911 and the first transmission rod 914 pass need to be staggered from the through holes through which the second lead screw 921 and the second transmission rod 924 pass, so as not to interfere with each other.

[0067] When it is necessary to move the transfer box 100, the first motor 913 / second motor 923 can be started. Taking the movement of the transfer box 100 along the first direction as an example, after the first motor 913 is started, the first lead screw 911 rotates, and the transfer box 100 moves along the axis of the first lead screw 911. At this time, the rollers at both ends of the first action rod will also roll to assist the movement of the transfer box 100.

[0068] Secondly, this application provides a solder joint detection method, implemented based on the aforementioned solder joint detection system, the solder joint detection method comprising: Step S100: The control module establishes a coordinate system and imports the theoretical coordinates of the weld points and the corresponding qualified appearance images.

[0069] In this context, the theoretical coordinates of the solder joints are obtained based on product design data, representing the theoretical coordinates of all solder joints to be inspected. The "appearance-qualified image" refers to a photograph of a solder joint that has passed inspection, obtained from historical records. An appearance-qualified image can be a photograph of a solder joint that has passed inspection and is located at the theoretical coordinates of the target solder joint, or it can be a photograph of a solder joint at other coordinates. In this embodiment, the appearance-qualified image is a photograph of a solder joint that has passed inspection and is located at the theoretical coordinates of the target solder joint; there is a one-to-one correspondence between the theoretical coordinates and the appearance-qualified image.

[0070] The robot connects to the gun changing plate 810, which moves the entire weld point inspection system to the inspection station of the sheet metal part to be inspected. The support frame 800 is precisely installed on the fixture at the inspection station by the positioning pin 821.

[0071] The control module establishes a coordinate system based on the fixture reference plate at the inspection station and calibrates the initial position of the ultrasonic probe 400. At the same time, it imports the theoretical coordinates of all weld points to be tested and the appearance qualification images of the weld points with theoretical coordinates into the control module.

[0072] Step S200: Determine the target solder joint and move the ultrasonic probe 400 and image acquisition device above the target solder joint position.

[0073] Identify the target solder joint and read its corresponding theoretical coordinates.

[0074] Based on the theoretical coordinates of the target weld point, the control module automatically plans the optimal movement route for the moving box 100 and starts the drive mechanism 900 according to the optimal movement route. The first motor 913 and the second motor 923 drive the moving box 100 to move the ultrasonic probe 400 above the theoretical coordinates of the target weld point.

[0075] Step S300: Use the image acquisition module 700 to acquire the first image of the target solder joint, compare the first image with the theoretical coordinates of the target solder joint and the appearance qualified image corresponding to the theoretical coordinates of the solder joint, and determine the first detection result. The first detection result includes the appearance quality of the solder joint and the offset of the solder joint.

[0076] The image acquisition module 700 is activated, and the three vision lenses 710 capture images of the target solder joint area without blind spots, and transmit the acquired images to the control module.

[0077] The control module compares the acquired actual image (the first image) with the imported qualified appearance image to obtain the solder joint quality. The appearance quality of the solder joint includes qualified and unqualified. If the target solder joint is identified as a defective solder joint such as spatter, horseshoe, or half spot, it is unqualified; the rest are qualified.

[0078] At the same time, the control module automatically calculates the offset between the center of the approximate circle of the target solder joint and the center of the theoretical solder joint based on the image, thus obtaining the solder joint offset of the target solder joint.

[0079] Step S400: If the appearance quality of the target solder joint is unqualified and / or the offset of the solder joint is greater than or equal to the first threshold, then proceed to the detection of the next target solder joint.

[0080] If the first test result shows that the appearance quality of the target weld point is unqualified, the target weld point is marked as unqualified and does not need to be tested again using the ultrasonic probe 400. The first threshold can be set according to the actual situation. In this embodiment, the first threshold can be set to 5mm. If the offset of the target weld point is greater than 5mm, the target weld point will also be marked as unqualified and will not need to be tested by ultrasonic probe 400.

[0081] For defective weld points, the control module uploads the weld point appearance quality data and / or weld point position offset data to the visualization system in real time, automatically stores and monitors this data, and immediately triggers an audible and visual alarm to alert subsequent repair personnel to rework the defective weld points. A traceable repair record is also generated. The weld point offset data is also fed back to the welding robot's control system, providing data support for optimizing and adjusting the welding robot's welding parameters.

[0082] Then return to step S200 to redetermine the next target solder joint and inspect it.

[0083] Step S500: If the appearance quality of the target weld point is qualified and the offset of the weld point is less than the first threshold, then the ultrasonic probe 400 is moved to the actual position of the target weld point and ultrasonic testing is performed on the weld point to obtain a second test result. The second test result includes the weld point welding quality, which includes qualified and unqualified.

[0084] In this embodiment, before moving the ultrasonic probe 400 to the actual position of the target weld point, the weld point detection method further includes: calculating the actual position of the target weld point based on the theoretical coordinates and offset of the target weld point.

[0085] If the appearance of the target solder joint is qualified and the offset of the solder joint is less than the first threshold, such as 5mm, the control module determines the actual position coordinates of the target solder joint based on the theoretical coordinates of the solder joint and the offset of the solder joint, and corrects the ultrasonic probe 400 to the actual position coordinates of the target solder joint.

[0086] The telescopic rod 300 extends downward, bringing the ultrasonic probe 400 closer to the target welding point. During this process, the control module controls the coupling agent conduit 420 to deliver the coupling agent to the drain hole 410 of the ultrasonic probe 400, and the coupling agent is discharged from the drain hole 410.

[0087] The telescopic rod 300 continues to extend downwards, and the detection surface of the ultrasonic probe 400 contacts the target welding point. As the telescopic rod 300 continues to extend downwards, the spring 500 gradually compresses. The pressure sensor collects the pressure of the spring 500 in real time. When the pressure value fed back by the pressure sensor reaches the preset maximum pressure threshold, the telescopic rod 300 stops extending. At this time, the ultrasonic probe 400 is completely in contact with the target welding point.

[0088] The control module adjusts the parameters of the ultrasonic probe 400, starts the ultrasonic probe 400 to detect the target weld point, and obtains the second detection result.

[0089] Step S600: If the welding quality of the target weld point is unqualified, the target weld point is marked as unqualified; if the welding quality of the target weld point is qualified, the telescopic rod 300 retracts, the current target weld point detection is completed, the next target weld point is determined, and the process returns to step S200.

[0090] For unqualified weld points, the control module uploads the weld quality data to the visualization system in real time, automatically stores and monitors the data, and immediately triggers an audible and visual alarm to remind subsequent repair personnel to rework the unqualified weld points and generate traceable inspection records.

[0091] Step S700: Determine whether all solder joints have been inspected. If not, return to step S200. If they have been inspected, the telescopic rod 300 retracts and the ultrasonic probe 400 moves to the initial position.

[0092] In step S800, the robot connects to the gun changing plate 810, and the entire weld point inspection system is sent away from the inspection station.

[0093] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” as used herein may also include the plural forms. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore indicate the presence of the stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not construed as requiring them to be performed in a particular order described or illustrated unless the order of performance is explicitly indicated. It should also be understood that additional or alternative steps may be used.

[0094] Although terms such as first, second, third, etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as the second element, component, region, layer, or segment without departing from the teachings of the exemplary embodiments.

[0095] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A solder joint inspection system, characterized in that, include: Line shift box (100); A connecting seat (200) is disposed on the first side of the moving box (100); Telescopic rod (300), the telescopic rod (300) is fixedly connected between the moving box (100) and the connecting seat (200); An ultrasonic probe (400) is disposed on the first side of the connector (200); A spring (500) and a spring seat (600) are provided. The spring seat (600) is disposed on the first side of the connecting seat (200) and connected to the connecting seat (200). The two ends of the spring (500) are respectively connected to the spring seat (600) and the ultrasonic probe (400). A pressure sensor is provided inside the spring seat (600), and the pressure sensor can detect the pressure of the spring (500). as well as The control module is coupled to the telescopic rod (300) and the pressure sensor. The control module can control the telescopic rod (300) to extend or retract according to a preset maximum pressure threshold.

2. The weld joint detection system according to claim 1, characterized in that, The connecting seat (200) is provided with a connecting hole, and the spring seat (600) is configured as a hollow structure. The spring seat (600) is threadedly connected to the connecting hole of the connecting seat (200).

3. The weld joint detection system according to claim 2, characterized in that, A connecting flange (310) is provided at one end of the telescopic rod (300) near the connecting seat (200); The connecting seat (200) is spaced apart from the connecting flange (310) and connected by one or more bolts.

4. The weld joint detection system according to claim 3, characterized in that, The ultrasonic probe (400) has a detection surface and one or more drainage holes (410) arranged around the detection surface; as well as A coupling agent conduit (420) passes through the connecting flange (310), the spring seat (600), and the spring (500). The coupling agent conduit (420) is coupled to the control module and communicates with the drain hole (410).

5. The weld joint detection system according to claim 4, characterized in that, The ultrasonic probe (400) also includes a chamfered surface, which is disposed around the detection surface and inclined relative to the detection surface, and one or more drainage holes (410) are spaced apart on the chamfered surface.

6. The weld joint detection system according to claim 1, characterized in that, The weld joint detection system also includes an image acquisition module (700), which includes one or more vision lenses (710), which are disposed around the ultrasonic probe (400) and fixedly connected to the connector (200). The image acquisition module (700) is coupled to the control module.

7. The weld joint detection system according to claim 1, characterized in that, The weld joint detection system also includes: Support frame (800), on which a gun changing disc (810) is provided; and A drive mechanism (900) is installed inside the support frame (800) and connected to the moving box (100). The drive mechanism (900) is capable of driving the moving box (100) to move.

8. The weld joint detection system according to claim 7, characterized in that, The support frame (800) includes: Multiple support legs (820); A first connecting frame (830) is installed between a plurality of the support legs (820) for connecting the gun changing disc (810). The second connecting frame (840) is mounted between the plurality of support legs (820) and located on the first side of the first connecting frame (830) for connecting the drive mechanism (900).

9. The weld joint detection system according to claim 7, characterized in that, The drive mechanism (900) includes: A first moving module (910) is slidably connected to the second connecting frame (840) and connected to the moving box (100), capable of driving the moving box (100) to move along a first direction; and / or The second moving module (920) is slidably connected to the second connecting frame (840) and connected to the moving box (100), and can drive the moving box (100) to move along the second direction.

10. A method for detecting solder joints, characterized in that, Based on the solder joint detection system according to any one of claims 1-9, the solder joint detection method includes: The control module establishes a coordinate system and imports the theoretical coordinates of the weld points and the corresponding qualified appearance images. Once the target weld point is identified, the ultrasonic probe (400) and image acquisition module (700) are moved to a position above the target weld point. The first image of the target solder joint is acquired using the image acquisition module (700), and the first image is compared with the theoretical coordinates of the target solder joint and the appearance qualified image corresponding to the theoretical coordinates of the solder joint to determine the first detection result. The first detection result includes the appearance quality of the solder joint and the offset of the solder joint. If the appearance quality of the target solder joint is unqualified and / or the offset of the solder joint is greater than or equal to the first threshold, then the next target solder joint is detected. If the appearance quality of the target weld point is qualified and the offset of the weld point is less than the first threshold, the ultrasonic probe (400) is moved to the actual position of the target weld point and ultrasonic testing is performed on the target weld point to obtain a second test result, the second test result including the welding quality of the weld point.

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