A detection mechanism for detecting surface defects of shaft products

Abstract

The application provides a kind of detection mechanism for detecting surface defects of shaft products, which comprises a machine tool truss, a feeding conveyor, a magnetic particle flaw detector, a defect detection area, a demagnetization area and a discharging conveyor, a truss manipulator is slidably arranged on the machine tool truss, the feeding conveyor is used to convey the shaft products to be detected, the magnetic particle flaw detector is used to magnetize the conveyed shaft products, the defect detection area is used to detect defects of the magnetized shaft products, the demagnetization area is used to demagnetize the defect-detected shaft products, the discharging conveyor is used to discharge the demagnetized shaft products, and the truss manipulator is used to grasp the shaft products to be detected, the magnetized shaft products, the defect-detected shaft products and the demagnetized shaft products; the application improves the detection efficiency, detection accuracy and detection reliability of surface defects of shaft products, improves the automation degree of defect detection, and reduces the labor intensity of workers.

Description

Technical Field

[0001] This application relates to the field of flaw detection technology for shaft products, and in particular to a testing organization for detecting surface defects in shaft products. Background Technology

[0002] Shaft products (such as plain shafts and hollow shafts) are indispensable key components in the industrial field, and their quality directly affects the operational stability and safety of the entire mechanical system. However, during the manufacturing process of shaft products, various defects inevitably appear on their surfaces due to the influence of materials, processes, equipment, and other factors, such as cracks, scratches, and pits. These defects not only affect the appearance quality of shaft products but also seriously impact their performance and may even lead to safety accidents. Therefore, timely and accurate detection of surface defects in shaft products is of great significance for ensuring product quality, improving production efficiency, and reducing safety risks.

[0003] Currently, the detection of surface defects in shaft products mainly relies on manual visual inspection or simple mechanical measuring tools. There is a lack of automated equipment for detecting surface defects in shaft products, which results in low efficiency, requires a large amount of labor intensity for staff, and makes it difficult to guarantee the accuracy and reliability of the detection.

[0004] Therefore, there is a need for a testing organization to detect surface defects in shaft products, in order to improve the accuracy, efficiency, and reliability of the detection of surface defects in shaft products, and reduce the labor intensity of workers. Summary of the Invention

[0005] In view of the shortcomings of the prior art described above, this application provides a testing mechanism for detecting surface defects in shaft products to solve the above-mentioned technical problems.

[0006] According to one aspect of the embodiments of this application, a detection mechanism for detecting surface defects in shaft products is provided. The detection mechanism includes: a machine tool truss, with a loading conveyor, a magnetic particle inspection machine, a defect detection area, a demagnetization area, and an unloading conveyor sequentially arranged from one end of the lower part of the machine tool truss to the other. A truss manipulator is slidably mounted on the machine tool truss. The loading conveyor is used to transport the shaft product to be inspected toward the magnetic particle inspection machine. The magnetic particle inspection machine is used to magnetize the transported shaft product. The defect detection area is used to process the magnetized shaft product. Magnetic powder is applied to shaft products, and defect detection is performed on the shaft products after magnetic powder application; the demagnetization area is used to demagnetize the shaft products after defect detection; the unloading conveyor is used to unload and convey the demagnetized shaft products; the gantry robot is used to pick up the shaft products to be inspected onto the magnetic powder flaw detector; to pick up the magnetized shaft products onto the defect detection area; to pick up the defect-detected shaft products onto the demagnetization area; and to pick up the demagnetized shaft products onto the unloading conveyor.

[0007] In one embodiment of this application, the magnetic particle inspection machine includes: a magnetizing stage and first driving devices fixedly installed on both sides of the magnetizing stage; each first driving device is used to drive an energized gripper; two energized grippers are arranged opposite to each other; the distance between the two energized grippers is greater than the length of the shaft product to be inspected; the first driving device is used to drive the energized grippers to move when the gantry robot grips the shaft product to be inspected and lowers it by a first preset descent distance, until the moving distance of the energized grippers reaches the preset distance.

[0008] In one embodiment of this application, the first driving device includes: a first servo motor and a lead screw; The first servo motor is fixedly mounted on the magnetization stage. The first servo motor is driven and connected to the lead screw. The lead screw is rotatably connected to the magnetization stage. An insulating pad is fixedly provided on the movable seat of the lead screw. The power connector is fixed on the insulating pad.

[0009] In one embodiment of this application, the defect detection area includes: a defect detection table, a magnetic powder spraying device, a defect detection fixture, and a lighting system; the defect detection fixture is fixed on the defect detection table and is used to clamp the magnetized shaft product; the magnetic powder spraying device is disposed on the defect detection table and located outside the darkroom, and is used to apply magnetic powder to the clamped shaft product; the lighting system is disposed inside the darkroom, which covers part of the defect detection table, and is used to perform defect detection on the shaft product after the magnetic powder has been applied.

[0010] In one embodiment of this application, the defect detection fixture includes: a first slide rail, a first sliding plate, and a first clamp; the first clamp is fixed on the first sliding plate and is used to clamp the magnetized shaft product; the first slide rail is fixedly installed on the defect detection table; the first sliding plate is slidably connected to the first slide rail.

[0011] In one embodiment of this application, the demagnetizing area includes: a demagnetizing table, a through-type demagnetizer, a second sliding plate, a second clamp, and a second driving device; the through-type demagnetizer is installed in the middle area of ​​the demagnetizing table and is used to demagnetize the shaft products after defect detection; a second slide rail is fixedly installed on the demagnetizing table, the second sliding plate is slidably connected to the second slide rail, and the second clamp is fixedly installed on the second sliding plate and is used to clamp the shaft products after defect detection; the second slide rail passes through the conveying channel of the through-type demagnetizer; the width of the second sliding plate is smaller than the width of the conveying channel of the through-type demagnetizer; the second driving device is used to drive the second sliding plate to move relative to the second slide rail, and the second sliding plate drives the shaft products after defect detection to pass through the conveying channel of the through-type demagnetizer from one end of the second slide rail to the other end of the second slide rail.

[0012] In one embodiment of this application, the unloading conveyor includes: a conveyor for defective shaft products and a conveyor for qualified shaft products; the gantry robot is used to pick up the demagnetized defective shaft products onto the conveyor for defective shaft products; and is also used to pick up the demagnetized qualified shaft products onto the conveyor for qualified shaft products; the conveyor for defective shaft products is located at the middle position of the demagnetizing platform and is used to convey the demagnetized defective shaft products; the conveyor for qualified shaft products is located at the end position of the demagnetizing platform and is used to convey the demagnetized qualified shaft products.

[0013] In one embodiment of this application, the gantry manipulator includes: a movable seat, a third drive device, a telescopic device, a rotating device, and a mechanical gripper; the movable seat is slidably connected to the machine tool gantry; the third drive device is used to drive the movable seat to slide on the machine tool gantry; the telescopic device is fixedly connected to the movable seat, the rotating device is drivenly connected to the telescopic device, and the mechanical gripper is drivenly connected to the rotating device; the mechanical gripper is used to grip the shaft product to be inspected, the magnetized shaft product, the shaft product after defect detection, or the demagnetized shaft product.

[0014] In one embodiment of this application, the rotating device includes: a drive motor, a driving gear, and a driven gear; the drive motor is fixedly connected to the driving end of the telescopic device, the driving gear is coaxially connected to the output shaft of the drive motor, the driven gear is rotatably connected to the driving end of the telescopic device, the driven gear meshes with the driving gear, and the driven gear is fixedly connected to the fixed end of the mechanical gripper.

[0015] In one embodiment of this application, the testing mechanism further includes a buffer conveyor line located between the magnetic particle flaw detector and the defect detection area, for conveying the magnetized shaft product at a preset conveying speed.

[0016] The beneficial effects of this application are as follows: This application includes a machine tool truss, with a loading conveyor, a magnetic particle inspection machine, a defect detection area, a demagnetizing area, and an unloading conveyor sequentially arranged from one end of the machine tool truss to the other. A truss robot is slidably mounted on the machine tool truss. The loading conveyor is used to transport the shaft products to be inspected to the magnetic particle inspection machine. The magnetic particle inspection machine is used to magnetize the transported shaft products. The defect detection area is used to apply magnetic powder to the magnetized shaft products and perform defect detection on the shaft products after applying magnetic powder. The demagnetizing area is used to demagnetize the shaft products after defect detection. The unloading conveyor... The platform is used for unloading and conveying demagnetized shaft products. The gantry robot is used to grab the shaft products to be inspected onto the magnetic particle inspection machine, grab the magnetized shaft products onto the defect detection area, grab the defect-detected shaft products onto the demagnetization area, and grab the demagnetized shaft products onto the unloading conveyor. Through the above structural setup, defects on the surface of shaft products can be detected, improving the efficiency, accuracy, and reliability of surface defect detection, increasing the automation level of surface defect detection of shaft products, and reducing the labor intensity of workers.

[0017] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort. In the drawings: Figure 1 This is a schematic diagram of the structure of a detection mechanism for detecting surface defects in shaft products, as illustrated in an exemplary embodiment of this application. Figure 2This is a schematic diagram of the structure of a rotating device shown in an exemplary embodiment of this application.

[0019] Figure label: 1-Machine tool gantry; 2-Feeding conveyor; 3-Magnetic particle inspection machine; 4-Buffer conveyor line; 5-Defect detection area; 6-Demagnetization area; 7-Conveyor for defective shaft products; 8-Conveyor for qualified shaft products; 9-Gantry robot; 11-Column; 31-Magnetization stage; 32-Electrified chuck; 33-First drive device; 51-Defect detection stage; 52-First slide rail; 53-First sliding plate; 54-First clamp; 55-Dark chamber; 61-Demagnetization stage; 62-Through-type demagnetizer; 63-Second sliding plate; 64-Second clamp; 91-Moving seat; 92-Telescopic device; 93-Rotating device; 94-Mechanical gripper; 931 - Drive motor; 932 - Drive gear; 933 - Driven gear. Detailed Implementation

[0020] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0021] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. The drawings only show the components related to this application and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0022] In the following description, numerous details are explored to provide a more thorough explanation of embodiments of the present application. However, it will be apparent to those skilled in the art that embodiments of the present application may be practiced without these specific details. In other embodiments, well-known structures and devices are shown in block diagram form rather than in detail to avoid obscuring embodiments of the present application.

[0023] The implementation details of the technical solutions in the embodiments of this application are described in detail below: Reference Figure 1 and Figure 2 As shown, the testing institutions include: The machine tool truss 1 has a loading conveyor 2, a magnetic particle flaw detector 3, a defect detection area 5, a demagnetization area 6 and a unloading conveyor 1 arranged sequentially from one end to the other. A truss robot 9 is slidably mounted on the machine tool truss 1. The feeding conveyor 2 is used to transport the shaft products to be inspected to the magnetic particle flaw detector 3. The magnetic particle flaw detector 3 is used to magnetize shaft products after they have been conveyed. Defect detection area 5 is used to apply magnetic powder to the magnetized shaft products and to perform defect detection on the shaft products after applying magnetic powder; Demagnetization area 6 is used to demagnetize shaft products after defect detection; The unloading conveyor is used to unload and convey demagnetized shaft products; The gantry robot 9 is used to pick up shaft products to be inspected onto the magnetic particle flaw detector 3; to pick up magnetized shaft products onto the defect detection area 5; to pick up shaft products after defect detection onto the demagnetization area 6; and to pick up demagnetized shaft products onto the unloading conveyor.

[0024] In one embodiment of this application, the shaft product to be inspected is conveyed to the magnetic particle inspection machine 3 via the feeding conveyor 2. The magnetic particle inspection machine 3 magnetizes the conveyed shaft product. Magnetic powder is applied to the magnetized shaft product through the defect detection area 5, and defect detection is performed on the shaft product after applying magnetic powder. The shaft product after defect detection is demagnetized through the demagnetization area 6. The demagnetized shaft product is unloaded and conveyed via the unloading conveyor. The gantry robot 9 picks up the shaft product to be inspected onto the magnetic particle inspection machine 3, picks up the magnetized shaft product onto the defect detection area 5, picks up the shaft product after defect detection onto the demagnetization area 6, and picks up the demagnetized shaft product onto the unloading conveyor. Through the above structural setup, defects on the surface of the shaft product can be detected, improving the detection efficiency, detection accuracy, and detection reliability of surface defects of the shaft product. It also improves the automation level of surface defect detection of the shaft product and reduces the labor intensity of the workers.

[0025] In one embodiment of this application, both the loading conveyor 2 and the unloading conveyor 2 include a conveyor chain, a support and guide assembly for supporting and guiding the conveyor chain, and a drive system for driving the conveyor chain to run on the support and guide assembly. The drive system is fixed on the support and guide assembly. Support frames for placing shaft products to be inspected are evenly installed on the conveyor chain. A vision inspection camera is installed on the column 11 of the machine tool gantry 1. This camera photographs the shaft products to be inspected on the feeding conveyor 2. A vision inspection algorithm identifies the images of the shaft products on the feeding conveyor 2, determining the quantity and position of each product. If the quantity of shaft products on the feeding conveyor 2 is zero, a voice prompt instructs the operator to place the products on the feeding conveyor 2. If the quantity is not zero, the movement distance of the conveyor chain is determined based on the placement position of the shaft products on the feeding conveyor 2. For example, if the placement position of the shaft products on the feeding conveyor 2 is... If the rightmost position is the location of the shaft product to be inspected, the conveyor chain travels zero distance. At this point, the gantry robot 9 is controlled to grab the shaft product to be inspected on the rightmost position. If the shaft product to be inspected on the loading conveyor 2 is placed in the second position from the right, the conveyor chain travels the distance between adjacent support frames. That is, after moving the shaft product to be inspected from the second position from the right to the rightmost position, the gantry robot 9 is controlled to grab the shaft product to be inspected on the rightmost position. If the shaft product to be inspected on the loading conveyor 2 is placed in the leftmost position, the conveyor chain travels twice the distance between adjacent support frames. That is, after moving the shaft product to be inspected from the leftmost position to the rightmost position, the gantry robot 9 is controlled to grab the shaft product to be inspected on the rightmost position.

[0026] In one embodiment of this application, the visual detection algorithm can refer to the related technology to identify the image of the shaft products to be detected on the feeding conveyor 2, and obtain the detection algorithm implementation of the number and position of the shaft products to be detected on the feeding conveyor 2, which will not be described in detail here.

[0027] In one embodiment of this application, the device controlling the operation of the loading conveyor 2, the unloading conveyor, the magnetic particle flaw detector 3, and the gantry robot 9 is a central control device, which can be a microcontroller or the like.

[0028] In one embodiment of this application, after the gantry robot 9 grasps the conveyed shaft product, it moves according to a first preset upward distance, a first preset horizontal distance, and a first preset downward distance. The conveyed shaft product is then positioned at a predetermined position on the magnetic particle inspection machine 3. After the magnetic particle inspection machine 3 clamps the conveyed shaft product, the gantry robot 9 releases it and magnetizes it using the magnetic particle inspection machine 3. After a predetermined magnetization time, the gantry robot 9 grasps the magnetized shaft product, while the magnetic particle inspection machine 3 releases it. The gantry robot 9 then moves according to a second preset upward distance, a second preset horizontal distance, and a second preset downward distance, placing the magnetized shaft product on the defect detection area 5. After positioning, the gantry robot 9 releases the magnetized shaft product, applies magnetic powder to the magnetized shaft product in the defect detection area 5, and performs defect detection on the shaft product after applying magnetic powder. Then, the gantry robot 9 grasps the defect-detected shaft product and moves it according to the third preset upward distance, the third preset horizontal distance, and the third preset downward distance. After placing the defect-detected shaft product in the predetermined position of the demagnetization area 6, the gantry robot 9 releases the defect-detected shaft product, demagnetizes it through the demagnetization area 6, grasps the demagnetized shaft product, moves it according to the fourth preset upward distance, the fourth preset horizontal distance, and the fourth preset downward distance, and places the demagnetized shaft product in the predetermined position of the unloading conveyor.

[0029] In one embodiment of this application, the first preset upward distance, the first preset horizontal distance, and the first preset downward distance are determined based on the rightmost position of the shaft product to be inspected placed on the feeding conveyor 2 and the predetermined position on the magnetic particle flaw detector 3. The second preset upward distance, the second preset horizontal distance, and the second preset downward distance are determined based on the predetermined position on the magnetic particle flaw detector 3 and the predetermined position on the defect detection area 5. The third preset upward distance, the third preset horizontal distance, and the third preset downward distance are determined based on the predetermined position on the defect detection area 5 and the predetermined position on the demagnetization area 6. The fourth preset upward distance, the fourth preset horizontal distance, and the fourth preset downward distance are determined based on the end position of the demagnetization area 6 and the predetermined position on the unloading conveyor.

[0030] In one embodiment of this application, the distance the gantry robot 9 moves after grasping and conveying the shaft product is determined by the current position of the gantry robot 9 and the rightmost position of the shaft product to be inspected placed on the feeding conveyor 2. The distance the gantry robot 9 moves after grasping the magnetized shaft product is determined by the current position of the gantry robot 9 and the predetermined position on the magnetic particle flaw detector 3. The distance the gantry robot 9 moves after grasping the shaft product after defect detection is determined by the current position of the gantry robot 9 and the predetermined position on the defect detection area 5. The distance the gantry robot 9 moves after grasping the demagnetized shaft product is determined by the current position of the gantry robot 9 and the position of the demagnetized shaft product (i.e., the end position of the demagnetization area 6, i.e., the demagnetization area 6 is one end of the defect detection area 5).

[0031] In one embodiment of this application, the gantry robot 9 can be configured as one or more. When there are multiple gantry robots 9, each gantry robot 9 is responsible for performing different gripping tasks. For example, when there are two gantry robots 9, one gantry robot 9 is responsible for gripping the shaft product to be inspected onto the magnetic particle flaw detector 3 and gripping the magnetized shaft product onto the defect detection area 5, while the other gantry robot 9 is responsible for gripping the defect-detected shaft product onto the demagnetization area 6; and for gripping the demagnetized shaft product onto the unloading conveyor.

[0032] In one embodiment of this application, the magnetic particle flaw detector 3 includes: Magnetizing platform 31, and first drive device 33 fixedly installed on both sides of magnetizing platform 31; Each first drive device 33 is used to drive one energized chuck 32; the two energized chucks 32 are arranged opposite to each other; the distance between the two energized chucks 32 is greater than the length of the shaft product to be inspected; The first drive device 33 is used to drive the energized chuck 32 to move when the gantry robot 9 grips the shaft product to be inspected and lowers it by a first preset descent distance, until the energized chuck 32 moves a preset distance.

[0033] In one embodiment of this application, the predetermined position on the magnetic particle flaw detector 3 is the spatial position between two energized grippers 32, and the distances between the two ends of this spatial position and the ends of the two energized grippers 32 are equal. When the conveyed shaft product is placed in this spatial position, the gantry robot 9 sends a gripping completion signal to the central control device. The central control device controls the two first drive devices 33 to work simultaneously, driving the two energized grippers 32 to move simultaneously toward the conveyed shaft product. After both energized grippers 32 have moved a preset distance, the two energized grippers 32 clamp the conveyed shaft product. At this time, the two first drive devices 33 send a clamping signal to the central control device. Upon receiving the completion signal, the central control equipment controls the gantry robot 9 to release the conveyed shaft product. After the gantry robot 9 sends the release signal to the central control equipment, the central control equipment controls the two energized grippers 32 to energize the conveyed shaft product. After the energization time of the two energized grippers 32 reaches the predetermined time, the central control equipment controls the two energized grippers 32 to de-energize. At this time, the central control equipment controls the gantry robot 9 to grasp the magnetized shaft product and controls the two first drive devices 33 to work simultaneously to release the magnetized shaft product. The gantry robot 9 places the magnetized shaft product at the predetermined position on the defect detection area 5.

[0034] In one embodiment of this application, the first driving device 33 includes: First servo motor, lead screw; The first servo motor is fixedly mounted on the magnetization stage 31. The first servo motor is connected to the lead screw drive. The lead screw is rotatably connected to the magnetization stage 31. An insulating pad is fixedly provided on the moving seat 91 of the lead screw, and the power connector is fixed on the insulating pad.

[0035] In one embodiment of this application, the central control device controls two first drive devices 33 to operate simultaneously, driving two energized clamps 32 to move towards the conveyed shaft product. During this process, the first servo motor drives the lead screw to rotate forward, which in turn moves the movable seat 91 on the lead screw, thereby controlling the energized connector to move closer to the conveyed shaft product. During the release process of the magnetized shaft product, the central control device controls the two first drive devices 33 to operate simultaneously. During this process, the first servo motor drives the lead screw to rotate in the opposite direction, which in turn moves the movable seat 91 on the lead screw, thereby controlling the energized connector to move away from the conveyed shaft product, thus releasing the magnetized shaft product. The insulating pad prevents the energized connector from affecting the first servo motor when energized.

[0036] In one embodiment of this application, the mechanical gripper 94 of the gantry robot 9 is made of non-ferromagnetic steel, which reduces the influence of the mechanical gripper 94 on the magnetism of the magnetized shaft product when the mechanical gripper 94 grasps the magnetized shaft product.

[0037] In one embodiment of this application, the defect detection area 5 is provided with: Defect detection table 51, magnetic powder spraying device, defect detection fixture, lighting system; The defect detection fixture is fixed on the defect detection table 51. The defect detection fixture is used to hold the magnetized shaft products. The magnetic powder spraying device is set on the defect detection table 51 and located outside the dark chamber 55. The magnetic powder spraying device is used to apply magnetic powder to the clamped shaft products. The lighting system is installed in the darkroom 55, which covers part of the defect detection table 51. The lighting system is used to detect defects in shaft products after magnetic powder has been applied.

[0038] In one embodiment of this application, after the gantry robot 9 places the magnetized shaft product on the defect detection fixture (at a predetermined position on the defect detection area 5), ​​the gantry robot 9 sends a release signal to the central control device. The central control device controls the gantry robot 9 to release the magnetized shaft product and controls the magnetic powder spraying device to apply magnetic powder to the clamped shaft product. After the magnetic powder is applied to the clamped shaft product for a preset time, the central control device controls the magnetic powder spraying device to stop applying powder and provides a voice prompt. The operator then moves the defect detection fixture into the darkroom 55, and the applied magnetic powder is illuminated by the lighting system. Afterwards, the shaft products undergo defect detection, and the defective shaft products are marked. After the marking is completed or the shaft products after applying magnetic powder are deemed qualified, the staff moves the defect detection fixture outside the darkroom 55. The shaft products after defect detection return to the predetermined position on the defect detection area 5, and the staff issues a gripping command to the gantry robot 9 through the gripping button on the central control screen connected to the central control equipment. The gantry robot 9 then places the shaft products after defect detection in the predetermined position of the demagnetization area 6 (the first end of the demagnetization area 6, i.e., the end of the demagnetization area 6 closest to the defect detection area 5).

[0039] In one embodiment of this application, the magnetic powder spraying device includes: a powder storage box, a powder spraying pump, a powder spraying pipe, and a nozzle. The powder storage box stores magnetic powder, and the powder spraying pump is connected to the powder storage box. The powder spraying pump extracts and pressurizes the magnetic powder from the powder storage box. One end of the powder spraying pipe is connected to the powder spraying pump, and the other end of the powder spraying pipe is connected to the nozzle. The nozzle is mounted on the defect detection platform 51 and located outside the dark chamber 55, and is used to uniformly spray magnetic powder onto the clamped shaft product. When applying magnetic powder to the clamped shaft product, the central control equipment controls the powder spraying pump to start. The powder spraying pump extracts and pressurizes the magnetic powder from the powder storage box and then delivers it to the nozzle through the powder spraying pipe. The nozzle then uniformly sprays the magnetic powder onto the surface of the clamped shaft product to achieve the magnetic powder coverage effect required for defect detection.

[0040] In one embodiment of this application, the lighting system includes: multiple LED light sources, a condenser lens, and a light shield. The multiple LED light sources are evenly distributed in the dark chamber 55 to provide sufficient and uniform illumination. The condenser lens is disposed in front of each LED light source to focus the light emitted by the LED light source, so that the light is more concentrated on the shaft product after the magnetic powder is applied, thereby improving the clarity of defect detection. The light shield is disposed outside the condenser lens to prevent interference from external light and ensure a stable lighting environment in the dark chamber 55. During defect detection, the operator controls the LED light sources to be turned on by operating the central control equipment. After the light is focused by the condenser lens, it illuminates the shaft product, thereby clearly observing the defects on the surface of the shaft product.

[0041] In one embodiment of this application, the marking equipment can be a laser marking machine or a label pasting method, etc.

[0042] In one embodiment of this application, the defect detection fixture includes: First slide rail 52, first sliding plate 53, first clamp 54; The first clamp 54 is fixed on the first sliding plate 53, and the first clamp 54 is used to clamp the magnetized shaft products; The first slide rail 52 is fixedly installed on the defect detection table 51; The first sliding plate 53 is slidably connected to the first slide rail 52.

[0043] In one embodiment of this application, after the gantry robot 9 places the magnetized shaft product on the first clamp 54 (a predetermined position on the defect detection area 5), ​​magnetic powder is applied to the clamped shaft product by a magnetic powder spraying device. After the magnetic powder is applied to the clamped shaft product, the sliding plate is pulled into the dark chamber 55, thereby driving the shaft product with applied magnetic powder on the sliding plate into the dark chamber 55. After defect detection is performed on the shaft product with applied magnetic powder, and after marking the defective shaft product, the sliding plate is pushed out of the dark chamber 55 (i.e., the predetermined position on the defect detection area 5).

[0044] In one embodiment of this application, the demagnetization region 6 is provided with: Demagnetizing table 61, through-type demagnetizer 62, second sliding plate 63, second clamp 64, second drive device; The through-type demagnetizer 62 is installed in the middle area of ​​the demagnetizing table 61. The through-type demagnetizer 62 is used to demagnetize shaft products after defect detection. A second slide rail is fixedly installed on the demagnetizing table 61, and a second sliding plate 63 is slidably connected to the second slide rail. A second clamp 64 is fixedly installed on the second sliding plate 63 and is used to clamp the shaft products after defect detection. The second slide rail passes through the conveying channel of the through-type demagnetizer 62. The width of the second sliding plate 63 is smaller than the width of the conveying channel of the through-type demagnetizer 62. The second drive device is used to drive the second sliding plate 63 to move relative to the second slide rail. The second sliding plate 63 drives the shaft products after defect detection from one end of the second slide rail through the conveying channel of the through demagnetizer 62 to the other end of the second slide rail.

[0045] In one embodiment of this application, when the gantry robot 9 places the defect-detected shaft product at a predetermined position in the demagnetization area 6, the gantry robot 9 sends a grasping completion signal to the central control device and releases the defect-detected shaft product. The central control device controls the second drive device to operate, driving the second sliding plate 63 to slide along the second slide rail towards the through-type demagnetizer 62 and through the conveying channel of the through-type demagnetizer, moving to the other end of the second slide rail. During this process, the defect-detected shaft product is demagnetized by passing through the conveying channel of the through-type demagnetizer. When the demagnetized shaft product moves to the other end of the second slide rail (i.e., the sliding distance of the second sliding plate 63 driven by the second drive device reaches a preset sliding distance threshold), the second drive device sends a movement completion signal to the central control device. The central control device controls the gantry robot 9 to grasp the demagnetized shaft product and controls the second drive device to drive the sliding plate back to the initial position of the second slide rail.

[0046] In one embodiment of this application, the second driving device may be a servo electric cylinder or the like, and is not specifically limited here.

[0047] In one embodiment of this application, the unloading conveyor table includes: Defective shaft product conveyor 7 and qualified shaft product conveyor 8; The gantry robot 9 is used to pick up defective shaft products after demagnetization and place them on the defective shaft product conveyor 7; it is also used to pick up qualified shaft products after demagnetization and place them on the qualified shaft product conveyor 8. The defective shaft product conveyor 7 is located in the middle of the demagnetizing table 61 and is used to convey the defective shaft products after demagnetization. The qualified shaft product conveyor 8 is located at the end of the demagnetizing table 61 and is used to convey qualified shaft products after demagnetization.

[0048] In one embodiment of this application, an industrial camera is mounted on the lower surface of the machine tool gantry 1 above the demagnetizing table 61. The industrial camera is used to photograph the demagnetized shaft products on the demagnetizing table 61. The industrial camera is equipped with a label detection algorithm. If the label detection algorithm detects a defective label on the demagnetized shaft product, the demagnetized shaft product is determined to be defective. The central control device controls the gantry robot 9 to pick up the defective shaft product and place it at a predetermined position on the defective shaft product conveyor 7 (the end of the defective shaft product conveyor 7 near the demagnetizing area 6). If the label detection algorithm detects no defective label on the demagnetized shaft product, the demagnetized shaft product is determined to be qualified. The central control device controls the gantry robot 9 to pick up the qualified shaft product and place it at a predetermined position on the qualified shaft product conveyor 8 (the end of the qualified shaft product conveyor 8 near the demagnetizing area 6), thereby realizing the separate transportation of defective and qualified shaft products.

[0049] In one embodiment of this application, the gantry robot 9 includes: 91. Movable seat, third drive device, telescopic device, rotating device, mechanical gripper, and mechanical jaws; The movable seat 91 is slidably connected to the machine tool gantry 1; The third drive unit is used to drive the movable seat 91 to slide on the machine tool gantry 1; The telescopic device 92 is fixedly connected to the movable seat 91, the rotating device 93 is drivenly connected to the telescopic device 92, and the mechanical gripper 94 is drivenly connected to the rotating device 93. The mechanical gripper 94 is used to grip shaft products to be inspected, magnetized shaft products, shaft products after defect inspection, or demagnetized shaft products.

[0050] In one embodiment of this application, the third driving device includes a servo motor, a drive gear, and a rack. The servo motor is fixedly mounted on the movable base 91 and coaxially connected to the drive gear. The rack is fixedly connected to the machine tool gantry 1 and meshes with the drive gear. When the gantry robot 9 moves laterally on the machine tool gantry 1, the servo motor is controlled by the central control device to drive the drive gear to rotate. When the gantry robot 9 needs to be raised or lowered, the telescopic device 92 is controlled by the central control device to shorten or extend. When the gantry robot 9 needs to rotate, the rotating device 93 is controlled by the central control device to drive the mechanical gripper 94 to rotate.

[0051] In one embodiment of this application, the rotating device 93 includes: Drive motor 931, drive gear 932 and driven gear 933; The drive motor 931 is fixedly connected to the drive end of the telescopic device 92, the driving gear 932 is coaxially connected to the output shaft of the drive motor 931, the driven gear 933 is rotatably connected to the drive end of the telescopic device 92, the driven gear 933 meshes with the driving gear 932, and the driven gear 933 is fixedly connected to the fixed end of the mechanical gripper 94.

[0052] In one embodiment of this application, when the gantry manipulator 9 needs to rotate, the central control device drives the motor 931 to work and drive the active gear 932 to rotate forward or backward, thereby driving the driven gear 933 to rotate backward or forward, thereby realizing the forward or reverse rotation of the mechanical gripper 94.

[0053] In one embodiment of this application, when the gantry robot 9 picks up the conveyed shaft product and places it at a predetermined position on the magnetic particle flaw detector 3, and when the gantry robot 9 picks up the qualified shaft product and places it at a predetermined position on the qualified shaft product conveyor 8, the gantry robot 9 needs to rotate 90 degrees.

[0054] In one embodiment of this application, the testing agency further includes: Buffer conveyor line 4 is located between magnetic particle flaw detector 3 and defect detection area 5, and is used to convey magnetized shaft products at a preset conveying speed.

[0055] In one embodiment of this application, the buffer conveyor line 4 adopts the same structure as the loading conveyor 2. The buffer conveyor line 4 serves to temporarily store the magnetized shaft products. The gantry robot 9 places the conveyed shaft products at a predetermined position on the buffer conveyor line 4 (the leftmost position on the buffer conveyor line 4). The preset conveying speed is set to meet the detection requirements of the defect detection area 5. The gantry robot 9 grasps the temporarily stored shaft products and places them at the predetermined position in the defect detection area 5 for defect detection according to a preset grasping cycle.

[0056] In one embodiment of this application, the inspection mechanism further includes safety protection devices. These devices are installed at locations such as the magnetic particle flaw detector 3, the defect detection area 5, and the demagnetization area 6. The safety protection devices include guardrails and safety light curtains. The guardrails prevent workers from accidentally contacting operating equipment parts, thus avoiding mechanical injury accidents. The safety light curtains detect whether objects enter the danger zone by emitting and receiving infrared rays. When a worker's hand or other object enters, the safety light curtain immediately sends a signal to the central control equipment. Upon receiving the signal, the central control equipment quickly stops the relevant equipment, thereby ensuring the personal safety of the workers.

[0057] This application involves setting up a machine tool gantry 1, with a loading conveyor 2, a magnetic particle inspection machine 3, a defect detection area 5, a demagnetization area 6, and an unloading conveyor 1 sequentially arranged from one end of the machine tool gantry 1 to the other. A gantry robot 9 is slidably mounted on the machine tool gantry 1. The loading conveyor 2 transports the shaft products to be inspected to the magnetic particle inspection machine 3. The magnetic particle inspection machine 3 magnetizes the transported shaft products. Magnetic powder is applied to the magnetized shaft products through the defect detection area 5, and defect detection is performed on the shaft products after applying magnetic powder. The demagnetization area 6 demagnetizes the shaft products after defect detection. The demagnetized shaft products are unloaded and conveyed by the unloading conveyor. The gantry robot 9 picks up the shaft products to be inspected and places them onto the magnetic particle inspection machine 3. The magnetized shaft products are then picked up onto the defect detection area 5, and the defect-detected shaft products are picked up onto the demagnetization area 6. Finally, the demagnetized shaft products are picked up onto the unloading conveyor. Through the above structural setup, defects on the surface of shaft products can be detected, improving the efficiency, accuracy, and reliability of surface defect detection. This also increases the automation level of surface defect detection for shaft products and reduces the labor intensity of workers.

[0058] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.

Claims

1. A testing mechanism for detecting surface defects in shaft products, characterized in that, The testing institutions include: A machine tool truss, wherein a feeding conveyor, a magnetic particle inspection machine, a defect detection area, a demagnetization area and a unloading conveyor are sequentially arranged from one end of the machine tool truss to the other end; and a truss manipulator is slidably mounted on the machine tool truss. The feeding conveyor is used to transport the shaft products to be inspected to the magnetic particle flaw detector. The magnetic particle inspection machine is used to magnetize shaft products after they have been transported. The defect detection area is used to apply magnetic powder to the magnetized shaft products and to perform defect detection on the shaft products after the magnetic powder has been applied. The demagnetizing area is used to demagnetize shaft products after defect detection; The unloading conveyor is used to unload and convey demagnetized shaft products; The truss robot is used to pick up the shaft product to be inspected onto the magnetic particle inspection machine; to pick up the magnetized shaft product onto the defect detection area; to pick up the defect-detected shaft product onto the demagnetization area; and to pick up the demagnetized shaft product onto the unloading conveyor.

2. The detection mechanism for detecting surface defects in shaft products according to claim 1, characterized in that, The magnetic particle flaw detector includes: A magnetization stage and a first driving device fixedly installed on both sides of the magnetization stage; Each first drive device is used to drive one energized chuck; the two energized chucks are arranged opposite each other; the distance between the two energized chucks is greater than the length of the shaft product to be tested; The first driving device is used to drive the energized chuck to move when the gantry robot grips the shaft product to be inspected and lowers it by a first preset descent distance, until the energized chuck moves a preset distance.

3. The detection mechanism for detecting surface defects in shaft products according to claim 2, characterized in that, The first driving device includes: First servo motor, lead screw; The first servo motor is fixedly mounted on the magnetization stage. The first servo motor is driven and connected to the lead screw. The lead screw is rotatably connected to the magnetization stage. An insulating pad is fixedly provided on the movable seat of the lead screw. The power connector is fixed on the insulating pad.

4. The detection mechanism for detecting surface defects in shaft products according to claim 1, characterized in that, The defect detection area is equipped with: Defect detection table, magnetic powder spraying device, defect detection fixture, lighting system; The defect detection fixture is fixed on the defect detection table and is used to clamp the magnetized shaft product. The magnetic powder spraying device is installed on the defect detection table and located outside the dark chamber. The magnetic powder spraying device is used to apply magnetic powder to the clamped shaft products. The lighting system is installed in a darkroom, which covers part of the defect detection station. The lighting system is used to detect defects in shaft products after magnetic powder has been applied.

5. The detection mechanism for detecting surface defects in shaft products according to claim 4, characterized in that, The defect detection fixture includes: First slide rail, first sliding plate, first clamp; The first clamp is fixed to the first sliding plate, and the first clamp is used to hold the magnetized shaft product; The first slide rail is fixedly installed on the defect detection platform; The first sliding plate is slidably connected to the first slide rail.

6. The detection mechanism for detecting surface defects in shaft products according to claim 1, characterized in that, The demagnetization area is provided with: Demagnetizing table, through-type demagnetizer, second sliding plate, second clamp, second drive device; The through-type demagnetizer is installed in the middle area of ​​the demagnetizing table, and is used to demagnetize the shaft products after defect detection; A second slide rail is fixedly installed on the demagnetizing table, a second sliding plate is slidably connected to the second slide rail, and a second clamp is fixedly installed on the second sliding plate. The second clamp is used to clamp the shaft products after defect detection. The second slide rail passes through the conveying channel of the through-type demagnetizer. The width of the second sliding plate is smaller than the width of the conveying channel of the through-type demagnetizer. The second driving device is used to drive the second sliding plate to move relative to the second slide rail. The second sliding plate drives the shaft product after defect detection to move from one end of the second slide rail through the conveying channel of the through-type demagnetizer to the other end of the second slide rail.

7. The detection mechanism for detecting surface defects in shaft products according to claim 6, characterized in that, The unloading conveyor table includes: Defective shaft product conveyor and qualified shaft product conveyor; The gantry robot is used to pick up defective shaft products after demagnetization and place them onto the defective shaft product conveyor; it is also used to pick up qualified shaft products after demagnetization and place them onto the qualified shaft product conveyor. The defective shaft product conveyor is located in the middle of the demagnetizing table and is used to convey the defective shaft products after demagnetization. The qualified shaft product conveyor is located at the end of the demagnetizing station and is used to convey the qualified shaft products after demagnetization.

8. The detection mechanism for detecting surface defects in shaft products according to claim 1, characterized in that, The gantry manipulator includes: Movable seat, third drive unit, telescopic device, rotating device, mechanical gripper; The movable seat is slidably connected to the machine tool truss; The third driving device is used to drive the movable seat to slide on the machine tool gantry; The telescopic device is fixedly connected to the movable seat, the rotating device is drivenly connected to the telescopic device, and the mechanical gripper is drivenly connected to the rotating device. The mechanical gripper is used to grasp the shaft product to be inspected, the magnetized shaft product, the shaft product after defect detection, or the demagnetized shaft product.

9. The detection mechanism for detecting surface defects in shaft products according to claim 8, characterized in that, The rotating device includes: Drive motor, driving gear, and driven gear; The drive motor is fixedly connected to the drive end of the telescopic device, the driving gear is coaxially connected to the output shaft of the drive motor, the driven gear is rotatably connected to the drive end of the telescopic device, the driven gear meshes with the driving gear, and the driven gear is fixedly connected to the fixed end of the mechanical gripper.

10. The detection mechanism for detecting surface defects in shaft products according to claim 1, characterized in that, The testing institution also includes: A buffer conveyor line is located between the magnetic particle flaw detector and the defect detection area, and is used to convey the magnetized shaft products at a preset conveying speed.

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