A dual-channel micro-hole existence detection method and system

Abstract

This invention provides a dual-channel micro-hole presence detection method and system. The method includes: positioning a first product and a second product at the first and second detection positions of a material loading mechanism, respectively, establishing a product channel correspondence, and after confirming the pressing state, forming an outer circumferential seal between the first and second hollow inflatable punches and the corresponding product sockets; generating sealing reference data through short-term low-pressure test inflation, and after confirming that the first and second detection channels meet the sealing detection conditions, applying controlled reverse release pulses to collect pressure recovery data and generating reverse release response data; subsequently performing graded forward inflation based on the reverse release response data, collecting the pressure rise slope, pressure delay abrupt change point, secondary release step amplitude, and final stage stabilization residual pressure to generate a pressure response signature; and finally comparing the pressure response signature with a preset micro-hole presence determination rule.

Description

Technical Field

[0001] This invention relates to the field of pinhole detection technology, and in particular to a dual-channel pinhole presence detection method and system. Background Technology

[0002] Micro-hole parts are often used in precision fluid control components such as fuel injection devices in automotive fuel engines. Whether the channels are truly open and whether the orifices are blocked or obstructed directly affects the flow of subsequent media. Therefore, each part needs to be inspected during mass production.

[0003] Existing detection methods mainly include manual light detection, visual inspection, and barometric pressure detection. Manual light detection relies on human observation and is greatly affected by aperture size, spherical cavity structure obstruction, ambient light, and human fatigue, making it prone to missed detections and difficult to trace the results. While visual inspection can improve observation accuracy, it is easily affected by depth of field, oil stains, reflections, and edge obstruction for tiny holes located in spherical cavities, recesses, or reflective areas, resulting in insufficient on-site stability.

[0004] Air pressure testing typically involves sealing an inflatable punch with the structure near the product's orifice, then injecting compressed air into the product, and determining whether the micro-orifice is open based on pressure changes in the air path. This method improves testing efficiency, but existing methods often rely on the pressure value after a single positive inflation or preset pressure limits as the basis for judgment, making it difficult to identify changes in the orifice's condition due to variations in airflow direction or pressure.

[0005] Therefore, this invention proposes a dual-channel micro-orifice presence detection method and system. The information disclosed in the background section is only for enhancing understanding of the background of this disclosure and may therefore contain prior art information that is not common knowledge to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of existing technologies by providing a dual-channel micropore presence detection method and system, thereby resolving the technical problems mentioned in the background section.

[0007] To achieve the above objectives, the present invention provides the following technical solution: A dual-channel method for detecting the presence of micropores includes the following steps: S1. Position the first product and the second product at the first detection position and the second detection position of the loading mechanism, establish the product channel correspondence between the first product and the first detection channel, and between the second product and the second detection channel, collect the pressing status data, and generate dual-channel positioning confirmation information; S2. Drive the dual-channel inflation assembly to rise according to the dual-channel positioning confirmation information, so that the first hollow inflation punch, the second hollow inflation punch and the corresponding product ball socket form an outer circumferential seal, perform short-term low-pressure test inflation, collect sealing status data, and form sealing reference data. S3. After the sealing detection conditions are met in the first and second detection channels, a controlled reverse release pulse is applied based on the first and second effective sealing detection gas paths, pressure recovery data is collected, and reverse release response data is formed. S4. Determine the graded forward inflation parameters based on the reverse release response data, perform graded forward inflation on the first and second detection channels, and collect the pressure rise slope, pressure delay abrupt change point, secondary release step amplitude and final stage stabilization residual pressure to form a pressure response signature. S5. Compare the pressure response signature with the preset micro-hole existence determination rules, determine the corresponding product as having one of the following detection results: micro-hole existence, blind hole, severely blocked hole, or variable obstruction hole, and output production control and traceability data according to the product channel correspondence.

[0008] S1 specifically includes: placing the first product in the first detection position and the second product in the second detection position; reading the material loading mechanism number, detection position number, detection channel number, and product detection sequence number; establishing the product channel correspondence between the first product and the first detection channel, and between the second product and the second detection channel; and confirming the placement direction based on the planar deviation of the ball socket center relative to the channel axis projection point; after the product channel correspondence is valid, controlling the upper pneumatic pressing mechanism to press down; collecting the pressing displacement, pressing holding pressure, and positioning signal through intelligent sensors to form pressing status data; judging the stable positioning state based on the planar deviation, pressing displacement deviation, pressing holding pressure, and holding time; and generating dual-channel positioning confirmation information when the conditions are met.

[0009] S2 specifically includes: after receiving the dual-channel positioning confirmation information, driving the dual-channel inflation assembly to rise, so that the first hollow inflation punch enters the first product socket and the second hollow inflation punch enters the second product socket, and an outer circumferential seal is formed by the rubber sealing ring; confirming the sealing fit state based on the punch arrival signal, the rising stroke and the rubber sealing ring compression rate; performing short-term low-pressure test inflation on the first and second detection channels, collecting the punch arrival state, test inflation pressure, test holding pressure end pressure and test pressure decay rate to form the first sealing reference data and the second sealing reference data; judging whether each detection channel meets the sealing detection conditions based on the sealing reference data, and outputting the first effective sealing detection air path and the second effective sealing detection air path when they meet the conditions.

[0010] S3 specifically includes: after the first effective seal detection gas path and the second effective seal detection gas path are established, controlling the reverse release branch to connect the first detection channel and the second detection channel respectively, and applying a controlled reverse release pulse based on the trial inflation pressure, target release pressure, release duration and release number; after the pulse ends, the pressure recovery sampling window is activated, and the pulse end pressure, recovery process pressure sequence, recovery target pressure arrival time and window end pressure are collected through intelligent sensors and digital pressure display devices to obtain pressure recovery data; from the pressure recovery data, the pressure recovery time, residual pressure after recovery, pressure rebound amplitude and pressure rebound ratio are extracted to form the first reverse release response data and the second reverse release response data.

[0011] S4 specifically includes: determining the graded forward inflation parameters for the first and second detection channels based on the first and second reverse release response data, respectively. The graded forward inflation parameters include the forward inflation starting pressure, pressure step, number of inflation stages, and holding time for each stage; performing forward inflation from low to high on the first and second detection channels according to the graded forward inflation parameters, and collecting pressure sampling data within the forward inflation sampling window through intelligent sensors and digital pressure display devices, extracting the pressure rise slope, pressure delay abrupt change point, secondary release step amplitude, and residual pressure at each stage; and combining the sealing reference data, reverse release response data, and forward inflation pressure characteristics to form the pressure response signatures of the first and second products.

[0012] S5 specifically includes: calling the pressure response signatures of the first and second products, identifying stable release characteristics and continuous high pressure characteristics according to the preset micro-hole existence judgment rules, determining that products with stable release characteristics have micro-holes, and determining that products with continuous high pressure characteristics and no effective secondary release step are blind holes or severely blocked holes; calling the reverse release response data and graded forward inflation pressure characteristics for products not directly judged, identifying variable blocking holes based on the amplitude of the secondary release step, the sudden drop delay time, and the stable low point pressure after the sudden drop; binding the detection results according to the product channel correspondence, outputting release, rejection alarm, shutdown alarm or isolation re-inspection instructions, and generating traceability data.

[0013] A dual-channel micropore presence detection system includes: The positioning and pressing module is used to position the first product and the second product at the first detection position and the second detection position of the loading mechanism, respectively. The sealing reference module is used to drive the dual-channel inflation assembly to rise according to the dual-channel positioning confirmation information, so that the first hollow inflation punch and the second hollow inflation punch respectively form an outer peripheral seal with the corresponding product ball socket; The reverse release module is used to apply controlled reverse release pulses to the first and second detection channels based on the effective seal detection gas path; The graded inflation acquisition module is used to determine the graded forward inflation parameters based on the reverse release response data, and to perform graded forward inflation on the first detection channel and the second detection channel. The determination and traceability module is used to compare the pressure response signature with the preset micro-hole existence determination rules to determine whether the corresponding product has one of the following detection results: micro-hole presence, blind hole, severely blocked hole, or variable shielding hole.

[0014] The beneficial effects of this invention are as follows: This invention, by setting a controlled reverse release pulse before the graded forward inflation test, causes burrs, oil films, or debris at the micro-orifice to be disturbed by a reverse pressure differential before the forward inflation test. This exposes orifice blockages that are only temporarily compressed under a single forward pressure, reducing the possibility of misjudging variable blockages as blind or severely blocked orifices. By first confirming the effective sealing status of the first and second detection channels using sealing reference data before proceeding with the reverse release and graded forward inflation tests, it is possible to distinguish between insufficient peripheral sealing, abnormal punch mating, and micro-orifice abnormalities in the product, avoiding misjudgments due to abnormal detection air paths.

[0015] This invention combines reverse release response data, graded forward inflation pressure characteristics, and sealing reference data to form a pressure response signature. Instead of relying solely on single pressure limits, it can simultaneously identify the presence of micropores, blind holes, severely blocked holes, and variable obstruction holes, improving the accuracy of micropore detection. By establishing product channel correspondences for the first and second products respectively, and binding the detection results with the detection channel, loading mechanism, sealing reference data, reverse release response data, and pressure response signature, it avoids result confusion in dual-channel synchronous detection, improving the reliability of defective product rejection, re-inspection, and quality traceability.

[0016] This invention employs a graded forward inflation method from low to high, and determines the forward inflation parameters based on the reverse release response data. This allows for the identification of the release process of moving obstructions at the orifice without damaging the product structure. It is suitable for batch inspection of micro-holes in visually limited locations such as cavities and recesses. The PLC-controlled alarm system outputs release, rejection, shutdown, or isolation re-inspection commands, enabling inspection judgment to directly participate in production control. This improves the efficiency of simultaneous dual-product inspection, reduces reliance on manual re-judgment, and enhances quality consistency during batch production. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a dual-channel micropore presence detection method according to the present invention; Figure 2 This is a schematic diagram of the framework of a dual-channel micro-hole presence detection system according to the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Example 1: As Figure 1 As shown, this embodiment provides a dual-channel micro-orifice presence detection method, including the following steps: S1. Position the first product and the second product at the first detection position and the second detection position of the loading mechanism, establish the product channel correspondence between the first product and the first detection channel, and between the second product and the second detection channel, collect the pressing status data, and generate dual-channel positioning confirmation information; S2. Drive the dual-channel inflation assembly to rise according to the dual-channel positioning confirmation information, so that the first hollow inflation punch, the second hollow inflation punch and the corresponding product ball socket form an outer circumferential seal, perform short-term low-pressure test inflation, collect sealing status data, and form sealing reference data. S3. After the sealing detection conditions are met in the first and second detection channels, a controlled reverse release pulse is applied based on the first and second effective sealing detection gas paths, pressure recovery data is collected, and reverse release response data is formed. S4. Determine the graded forward inflation parameters based on the reverse release response data, perform graded forward inflation on the first and second detection channels, and collect the pressure rise slope, pressure delay abrupt change point, secondary release step amplitude and final stage stabilization residual pressure to form a pressure response signature. S5. Compare the pressure response signature with the preset micro-hole existence determination rules, determine the corresponding product as having one of the following detection results: micro-hole existence, blind hole, severely blocked hole, or variable obstruction hole, and output production control and traceability data according to the product channel correspondence.

[0020] S1 specifically includes the following sub-steps: S110. Establish the product channel correspondence between the first product and the second product: Place the first product to be tested at the first detection position of the loading mechanism, and place the second product to be tested at the second detection position of the loading mechanism. The first detection position is equipped with a first product positioning block that mates with the outer peripheral positioning surface of the first product, and the second detection position is equipped with a second product positioning block that mates with the outer peripheral positioning surface of the second product. Both the first product positioning block and the second product positioning block use the installation reference surface of the loading mechanism as the positioning reference.

[0021] After the material loading mechanism enters the inspection station, the PLC (Programmable Logic Controller) reads the material loading mechanism number, the first inspection station number, the second inspection station number, the current inspection batch number, and the inspection channel number through the RFID reader or barcode scanner set at the inspection station. It then binds the first product to the first inspection channel and the second product to the second inspection channel, generating a product channel correspondence.

[0022] Product channel correspondence refers to a data set that records the corresponding binding relationship between products, detection positions, material loading mechanisms and detection channels. It includes at least the material loading mechanism number, the first detection position number, the second detection position number, the first detection channel number, the second detection channel number, the first product detection sequence number, and the second product detection sequence number.

[0023] The product channel correspondence is used in S210 to determine the docking object of the first hollow inflatable punch and the second hollow inflatable punch, and in S530 to write the test results back to the corresponding product.

[0024] To confirm that the placement orientation of the first and second products meets the requirements for subsequent inflation testing, the PLC control alarm system retrieves the calibration coordinate data of the material loading mechanism and calculates the planar deviation of the ball socket center relative to the corresponding detection channel axis projection point: in, The deviation of the center of the ball socket of the product corresponding to the i-th detection channel from the projection point of the detection channel axis is expressed in mm; i is the detection channel number. Corresponding to the first detection channel, Corresponding to the second detection channel; and These are the horizontal and vertical coordinates of the ball socket center of the product corresponding to the i-th detection channel under the reference coordinates of the loading mechanism, respectively, in mm; and These are the horizontal and vertical coordinates of the projection point of the i-th detection channel axis in the reference coordinates of the loading mechanism, respectively, in mm. and It originates from the geometric calibration results of the product's positioning surface and positioning block in the material loading mechanism. and It originates from the assembly calibration results of the corresponding hollow inflatable punch relative to the material loading mechanism.

[0025] For example, for a ball-and-socket micro-hole product with an aperture of 0.4mm, the permissible plane deviation threshold is set to 0.08mm. When the plane deviation corresponding to the first product is 0.04mm and the plane deviation corresponding to the second product is 0.05mm, the PLC control alarm system confirms that the first product corresponds to the first detection channel and the second product corresponds to the second detection channel, and allows entry into S120; when the plane deviation corresponding to either product is greater than 0.08mm, a valid product channel correspondence is not generated, and a product placement deviation alarm is output.

[0026] S120. Collect pressing status data of the upper pneumatic pressing mechanism: After establishing an effective product channel correspondence, the PLC control alarm system controls the upper pneumatic pressing mechanism to move downwards, causing the first contour pressing block to press the first product, and the second contour pressing block to press the second product. During the downward pressing process of the upper pneumatic pressing mechanism, pressing status data is collected through intelligent sensors.

[0027] A smart sensor is a combination of sensors installed in a detection device that can collect displacement, pressure, air pressure or position signals and output digital detection signals. In this embodiment, the smart sensor includes at least a displacement sensor (preferably a high-precision grating ruler or laser displacement sensor with a resolution of not less than 0.01 mm) installed at the cylinder stroke end of the upper pneumatic pressing mechanism, a pressure sensor (preferably a high-frequency digital pressure sensor) installed at the pressing air path or the connection part of the pressing block, and a position detection switch installed at the pressing position.

[0028] The displacement sensor is used to collect the actual pneumatic pressure displacement, the pressure sensor is used to collect the pressure holding pressure, and the position detection switch is used to confirm whether the first and second contouring pressure blocks have entered the pressure holding position.

[0029] The PLC control alarm system compares the actual pneumatic pressing displacement collected by the intelligent sensor with the preset pressing displacement to obtain the pressing displacement deviation: in, This refers to the material displacement deviation, expressed in mm. The actual pneumatic material displacement collected by the displacement sensor is in mm. The pressure displacement is preset based on the height of the first and second products, the height of the bearing surface of the material loading mechanism, and the pressing position of the contour pressure block, and is expressed in mm. The values ​​are derived from real-time data collected by the displacement sensor. These are process parameters that are written into the PLC control and alarm system after the qualified products are calibrated by pressing during equipment setup.

[0030] For example, the preset material pressure displacement is 18.00 mm, the allowable material pressure displacement deviation is 0.10 mm, and the preset material pressure holding range is 0.25 MPa to 0.35 MPa. When the actual pneumatic material pressure displacement collected by the displacement sensor is 17.96 mm, the material pressure displacement deviation is 0.04 mm; simultaneously, the pressure sensor collects the material holding pressure at 0.30 MPa, the position detection switch continuously outputs a position signal, and the PLC control alarm system records that the first and second products are in the material holding state. If the actual pneumatic material pressure displacement is 17.75 mm, and the material pressure displacement deviation is 0.25 mm, even if the position detection switch outputs a position signal briefly, it is not considered a valid material pressure state.

[0031] S130: Generate dual-channel positioning confirmation information and use it as the basis for establishing the subsequent sealing detection air path: The PLC control alarm system determines whether the first and second products have completed stable positioning based on the product channel correspondence obtained in S110 and the material pressing status data obtained in S120. Stable positioning means that both the first and second products have completed the detection channel binding, and the upper pneumatic material pressing mechanism remains in the preset position and within the preset pressure range, so that the first and second products do not shift positions when the dual-channel inflation assembly rises and docks.

[0032] Stable positioning requires at least the following conditions to be met simultaneously: the product channel correspondence is valid; the planar deviations of the first and second products do not exceed the allowable planar deviation threshold; the pressure displacement deviation does not exceed the allowable pressure displacement deviation threshold; and the pressure holding pressure is within the preset pressure range and continuously reaches the preset holding time. Stable positioning is determined using the following formula: in, To ensure stable positioning results; The permissible plane deviation threshold is expressed in mm. The allowable material displacement deviation threshold is expressed in mm. The pressure holding pressure of the material, collected by the pressure sensor, is expressed in MPa. This is the preset lower limit of the material pressing pressure, in MPa; The preset upper limit of the material pressing pressure is in MPa; The duration for which the pressure is maintained continuously within the preset pressure range for the material to be pressed, measured in seconds; The preset holding time is expressed in seconds. The above thresholds are derived from the calibration results of qualified products, qualified material loading mechanisms, and qualified material pressing states during the equipment commissioning phase, and are stored in the PLC control alarm system.

[0033] For example, the allowable plane deviation threshold is 0.08 mm, the allowable pressure displacement deviation threshold is 0.10 mm, the preset pressure range is 0.25 MPa to 0.35 MPa, and the preset holding time is 0.30 s. When both the first and second products have completed product channel binding, the plane deviation of the two products is no greater than 0.08 mm, the pressure displacement deviation is 0.04 mm, and the pressure holding pressure is 0.30 MPa and continuously maintained for 0.35 s, the PLC control alarm system generates dual-channel positioning confirmation information.

[0034] The dual-channel positioning confirmation information includes at least the material loading mechanism number, the first detection channel number, the second detection channel number, the first product detection sequence number, the second product detection sequence number, the material pressure displacement deviation, the material pressure holding pressure, and the positioning confirmation time. This information is output to S210 as the starting basis for allowing the dual-channel inflation assembly to rise. If the material pressure holding pressure is 0.18 MPa, or the material pressure holding time is 0.12 s, the PLC control alarm system will not generate dual-channel positioning confirmation information and will output an alarm for insufficient material pressure or unstable positioning.

[0035] S2 specifically includes the following sub-steps: S210. Establish the sealing fit between the hollow inflatable punch and the corresponding product socket: After receiving the dual-channel positioning confirmation information output from S130, the PLC control alarm system allows the lower pneumatic ejector mechanism to drive the dual-channel inflatable assembly to move upward. The dual-channel inflatable assembly includes a first hollow inflatable punch and a second hollow inflatable punch. The first hollow inflatable punch corresponds to the first detection channel, and the second hollow inflatable punch corresponds to the second detection channel.

[0036] When the dual-channel inflation assembly rises, the first hollow inflation punch enters the first product socket, and the second hollow inflation punch enters the second product socket. The rubber sealing ring installed on the outer periphery of the hollow inflation punch is pressed between the corresponding hollow inflation punch and the corresponding product socket, forming an outer peripheral seal for the detection air path. This outer peripheral seal means that gas can only enter the product socket and micro-hole position through the hollow channel of the hollow inflation punch, and cannot leak out from between the outer periphery of the hollow inflation punch and the product socket.

[0037] To avoid relying solely on cylinder movement commands for seal confirmation, the PLC-controlled alarm system uses a combination of intelligent sensor data (punch positioning signal, dual-channel inflation assembly stroke, and rubber seal compression ratio) to confirm the seal fit. The rubber seal compression ratio is calculated using the following formula: in, Let be the compression ratio of the rubber seal ring of the i-th detection channel, and be a dimensionless ratio; The original height of the rubber seal ring of the i-th detection channel when it is not under pressure, in mm, is derived from the specifications of the rubber seal ring or the measurement value before assembly. This refers to the pressure height of the rubber sealing ring after the hollow inflation punch mates with the product's ball-and-socket seal, expressed in mm. It is derived from calculations based on the upward stroke of the dual-channel inflation assembly, the calibrated depth of the ball-and-socket seal, and the installation height of the rubber sealing ring. This calculation is used to determine whether the rubber sealing ring is within the compression range that allows for a stable seal without damaging the product.

[0038] For example, if the original height of the rubber seal ring when it is not compressed is 1.20 mm, and after the first hollow inflatable punch enters the first product socket, the compressed height of the rubber seal ring is calculated to be 0.96 mm based on the upward stroke and the calibrated depth of the socket, then the compression rate of the rubber seal ring in the first detection channel is 0.20.

[0039] When the preset acceptable compression ratio range is 0.15 to 0.25, the PLC control alarm system confirms that the first hollow inflation punch and the first product ball socket have achieved a sealed fit. If the compression ratio is 0.10, it indicates that the sealing ring is not tightened enough, and subsequent pressure data may include peripheral air leakage. If the compression ratio is 0.30, it indicates that the top pressure is too deep, which may change the state of the micro-orifice or damage the product. In neither of the above two situations, subsequent reverse release processing is not allowed.

[0040] S220. Collect sealing reference data of the first and second detection channels: After the first and second hollow inflation punches have completed the confirmation of their respective positions, the PLC control alarm system controls the first and second detection channels to perform short-term low-pressure test inflation respectively.

[0041] Specifically, the PLC-controlled alarm system outputs analog or digital control signals to the electro-proportional valve in the air circuit of the detection channel. This controls the air source to introduce compressed air into the corresponding detection channel at a test pressure lower than the staged forward inflation test pressure. Pressure changes are collected within a short period to confirm whether there is insufficient peripheral sealing between the hollow inflation punch and the product's ball socket, eccentric punch mating, or air circuit leaks. This short-term low-pressure test inflation is not used to directly determine the presence of micro-holes, nor is it used to determine whether the hole diameter is acceptable.

[0042] The intelligent sensor and digital pressure display device respectively collect the punch positioning signals of the first and second detection channels and probe the inflation pressure. The test pressure holding time, the test pressure holding end pressure, and the test pressure decay rate are combined with the rubber sealing ring compression rate to form the first sealing reference data and the second sealing reference data.

[0043] Sealing reference data refers to the set of data used to prove that the detection channel has effective sealing conditions before entering the reverse release pulse process. It includes at least the detection channel number, the punch position status, the rubber sealing ring compression rate, the test inflation pressure, the test holding pressure start and end time, the test holding pressure end pressure, and the test pressure decay rate.

[0044] The test pressure decay rate is calculated using the following formula: in, The test pressure attenuation rate of the i-th detection channel is expressed in MPa / s. The pressure at the end of the short-term low-pressure test inflation of the i-th detection channel is expressed in MPa. The pressure at the end of the test pressure holding for the i-th detection channel, in MPa; The time when the short-term low-pressure test inflation ends for the i-th detection channel is measured in seconds. The time when the test pressure holding ends for the i-th detection channel is measured in seconds. and Continuous sampling values ​​derived from digital pressure display devices or pressure sensors. and The sampling clock originates from the PLC-controlled alarm system.

[0045] For example, if the test inflation pressure of the first testing channel is set to 0.080 MPa, the test holding time is set to 0.10 s, the pressure at the end of the test inflation is 0.080 MPa, and the pressure at the end of the test holding is 0.074 MPa, then the test pressure decay rate of the first testing channel is 0.060 MPa / s. If the allowable test pressure decay rate obtained through equipment calibration is not greater than 0.080 MPa / s, then the sealing reference data of the first testing channel meets the subsequent testing requirements.

[0046] If the pressure at the end of the second detection channel test inflation is 0.080 MPa and the pressure at the end of the test holding pressure is 0.060 MPa, then the test pressure decay rate of the second detection channel is 0.200 MPa / s. The PLC control alarm system will prioritize determining that there is insufficient outer peripheral sealing or abnormal punch docking in the second detection channel, rather than directly interpreting the pressure drop as the second product hole being too large.

[0047] S230: Determine the sealing detection conditions and output the valid sealing detection gas path: The PLC control alarm system, based on the first and second sealing reference data formed in S220, determines whether the first and second detection channels meet the sealing detection conditions. The sealing detection conditions refer to the valid gas path conditions that the detection channels must meet before entering the reverse release process in S310; only when the sealing detection conditions are met can the subsequently collected reverse release response data and pressure response signature have a basis for determining the existence of micropores.

[0048] The sealing test conditions for each test channel include at least the following: the hollow inflation punch is in the correct position, the rubber sealing ring compression rate is within the preset compression rate range, the test inflation pressure is within the preset test pressure range, and the test pressure decay rate does not exceed the preset decay rate threshold.

[0049] The sealing test conditions are determined by the following formula: in, The result of the sealing test condition determination for the i-th test channel; This represents the position status of the hollow inflatable punch in the i-th detection channel; a value of 1 indicates that the punch is in place. Let be the compression ratio of the rubber seal ring of the i-th detection channel, and be a dimensionless ratio; This is the preset lower limit of compression ratio, and it is a dimensionless ratio. This is the preset upper limit of compression ratio, and it is a dimensionless ratio. The test inflation pressure for the i-th detection channel is expressed in MPa. The preset lower limit of the test pressure is in MPa; The upper limit of the preset test pressure is expressed in MPa. The test pressure attenuation rate of the i-th detection channel is expressed in MPa / s. This is the preset attenuation rate threshold, in MPa / s.

[0050] The above thresholds are derived from the calibration results of qualified products, qualified material loading mechanisms, qualified rubber seals, and qualified air sources during the equipment commissioning phase, and are stored in the PLC control alarm system.

[0051] For example, the preset compression ratio range is 0.15 to 0.25, the preset test pressure range is 0.075 MPa to 0.085 MPa, and the preset attenuation rate threshold is 0.080 MPa / s. If the punch position of the first detection channel is 1, the rubber sealing ring compression ratio is 0.20, the test inflation pressure is 0.080 MPa, and the test pressure attenuation rate is 0.060 MPa / s, then the first detection channel meets the sealing test conditions. If the punch position of the second detection channel is 1, the rubber sealing ring compression ratio is 0.13, the test inflation pressure is 0.080 MPa, and the test pressure attenuation rate is 0.110 MPa / s, then the second detection channel does not meet the sealing test conditions. The PLC control alarm system outputs an alarm indicating insufficient sealing in the second detection channel and prohibits entry into S310.

[0052] When both the first detection channel and the second detection channel meet the sealing detection conditions, the corresponding sealing detection gas path is recorded as the first effective sealing detection gas path and the second effective sealing detection gas path, and is output to S310 along with the first sealing reference data and the second sealing reference data.

[0053] S3 specifically includes the following sub-steps: S310, Apply controlled reverse release pulse based on effective seal detection gas path: After receiving the first effective seal detection gas path, the second effective seal detection gas path, the first seal reference data and the second seal reference data output by S230, the PLC control alarm system controls the first detection channel and the second detection channel to enter the reverse release process respectively.

[0054] Reverse release treatment refers to briefly lowering the pressure within the testing channel below the trial inflation pressure in the corresponding sealing reference data before the graded forward inflation test. This creates a pressure differential disturbance at the micro-orifice that is opposite to the direction of the graded forward inflation. This reverse release treatment is used to loosen any burrs, oil films, or debris that may be present at the micro-orifice and is not directly used as a basis for determining whether the micro-orifice is qualified or unqualified.

[0055] The reverse release pulse is generated by the reverse release branch. The reverse release branch refers to an exhaust or micro-negative pressure branch that is controlled to connect to either the first or second effective seal detection gas path. It may include a high-frequency solenoid valve controlled by the high-speed pulse output (PWM) terminal of the PLC, and a fast exhaust valve, micro-negative pressure generator, or low-pressure buffer chamber connected in series after the high-frequency solenoid valve. Millisecond-level pressure release control is achieved by precisely controlling the opening and closing time of the high-frequency solenoid valve.

[0056] The PLC control alarm system generates the reverse release pulse intensity for the corresponding detection channel based on the test inflation pressure, preset target release pressure, preset release duration, and preset release count in the sealing reference data. in, The reverse release pulse intensity of the i-th detection channel is expressed in MPa·s. The test inflation pressure obtained by the i-th detection channel in S220 is in MPa; The target pressure for the kth reverse release pulse is expressed in MPa. The duration of the k-th reverse release pulse is in seconds; n is the number of reverse release pulses, and k is the sequence number of the reverse release pulse, k=1,2,...,n. Derived from sealing reference data, , 'n' originates from the preset reverse release parameters in the PLC control alarm system.

[0057] For example, if the test inflation pressure of the first detection channel is 0.080 MPa, and the reverse release branch reduces the pressure of the first detection channel to 0.010 MPa and holds it for 0.05 s, and executes this twice, then the reverse release pulse intensity of the first detection channel is 0.007 MPa·s.

[0058] If, during the equipment commissioning phase, qualified samples confirm that the strength is sufficient to disturb the oil film at the orifice without causing product displacement or damaging the edge of the micro-hole, the PLC control alarm system will use this parameter as the reverse release parameter for the first detection channel. If the calculated reverse release pulse intensity exceeds the upper limit of the safe pulse intensity, the PLC control alarm system will reduce the target release pressure difference, shorten the release duration, or reduce the number of releases to prevent the reverse release process from altering the product's structural state.

[0059] S320. Acquire pressure recovery data after reverse release: After each reverse release pulse ends, the PLC control alarm system immediately activates the pressure recovery sampling window of the corresponding detection channel. The pressure recovery sampling window refers to the continuous sampling period from the end of the reverse release pulse until the pressure of the detection channel first recovers to the pressure corresponding to the preset recovery ratio, or until the preset sampling duration is reached.

[0060] The intelligent sensor and digital pressure display device continuously collect pressure values ​​within the pressure recovery sampling window. The collected data includes at least the pulse end pressure, the pressure sequence during the recovery process, the arrival time of the target recovery pressure, and the end pressure of the window. The pressure values ​​are derived from the pressure sensor or digital pressure display device of the corresponding detection channel, and the times are derived from the sampling clock of the PLC control alarm system.

[0061] Pressure recovery time is calculated using the following formula: in, The pressure recovery time for the i-th detection channel is expressed in seconds. The time of the end of the reverse release pulse of the i-th detection channel is expressed in seconds. For the first time, the pressure of the i-th detection channel is restored to The time is expressed in seconds (s). The preset recovery ratio is a dimensionless ratio. The test inflation pressure obtained by the i-th detection channel in S220 is expressed in MPa. and The sampling clock of the PLC-controlled alarm system records whether the pressure has reached the target level. It is calculated from the pressure sampling value and the corresponding test inflation pressure.

[0062] For example, if the initial inflation pressure of the first detection channel is 0.080 MPa and the preset recovery ratio is 0.80, then the target recovery pressure is 0.064 MPa. If the reverse release pulse of the first detection channel ends at 1.000 seconds and the pressure sampling value first reaches 0.064 MPa at 1.115 seconds, then the pressure recovery time of the first detection channel is 0.115 seconds. If the second detection channel uses the same release parameters, but the pressure only first reaches 0.064 MPa at 1.260 seconds, then the PLC control alarm system records that the second detection channel has a longer pressure recovery time.

[0063] This difference is not directly used by S320 to conclude that the product is unqualified, but rather serves as the original basis for S330 to generate reverse release response data.

[0064] S330. Generating First and Second Reverse Release Response Data: Based on the pressure recovery data collected in S320, the PLC control alarm system extracts the pressure recovery time, residual pressure after recovery, pressure rebound amplitude, and pressure rebound ratio from the first and second detection channels respectively, and generates first and second reverse release response data. Reverse release response data refers to the data set used to characterize the pressure recovery state of the detection channel after the reverse release pulse, and includes at least the detection channel number, reverse release pulse intensity, pressure recovery time, residual pressure after recovery, pressure rebound amplitude, pressure rebound ratio, and release anomaly marker.

[0065] The residual pressure after recovery is the pressure value at the end of the pressure recovery sampling window; the pressure rebound amplitude is the difference between the highest pressure and the pulse end pressure within the pressure recovery sampling window; the release anomaly flag is used to record situations where the pressure does not recover to the preset recovery ratio, the pressure recovery time exceeds the preset recovery time upper limit, or the pressure sampling is interrupted.

[0066] The pressure rebound ratio is calculated using the following formula: in, Let be the pressure rebound ratio of the i-th detection channel, and be a dimensionless ratio. The highest pressure of the i-th detection channel within the pressure recovery sampling window, in MPa; The pressure of the i-th detection channel at the end of the reverse release pulse is expressed in MPa. The test inflation pressure obtained by the i-th detection channel in S220 is expressed in MPa. and The pressure sampling sequence originates from within the pressure recovery sampling window. It is derived from sealing reference data.

[0067] For example, if the initial inflation pressure of the first detection channel is 0.080 MPa, the pressure at the end of the reverse release pulse is 0.010 MPa, and the highest pressure within the pressure recovery sampling window is 0.066 MPa, then the pressure rebound ratio of the first detection channel is 0.70. If, during equipment commissioning, the pressure rebound ratio of a normal through-hole is confirmed to be between 0.55 and 0.75, and the pressure recovery time does not exceed 0.150 s, then the PLC control alarm system records this result as the first reverse release response data. If the pressure rebound ratio of the second detection channel is also within this range, but the pressure recovery time reaches 0.260 s, then the PLC control alarm system writes a pressure recovery delay flag into the second reverse release response data.

[0068] The first reverse release response data and the second reverse release response data are output to S410 to determine the graded forward inflation parameters, and are combined with the forward inflation pressure characteristics in S430 to form the pressure response signatures of the first product and the second product.

[0069] S4 specifically includes the following sub-steps: S410. Perform graded forward inflation based on reverse release response data: After receiving the first and second reverse release response data output by S330, the PLC control alarm system determines the graded forward inflation parameters for the first and second detection channels, respectively. Graded forward inflation refers to introducing compressed air into the detection channel in multiple pressure levels from low to high, instead of using a one-time inflation of the target detection pressure, and retaining a sampling time at each pressure level to observe the opening, blocking, or delayed release status of the micro-orifice under the action of forward airflow.

[0070] The parameters for graded forward inflation include at least the forward inflation starting pressure, pressure gradient, number of inflation stages, and holding time for each stage. The forward inflation starting pressure and pressure gradient are determined by the PLC control alarm system based on the sealing reference data output by S230 and the reverse release response data output by S330. The number of inflation stages and holding time for each stage are determined by the pressure curve calibration results of qualified through-hole samples, blind-hole samples, and variable-obstruction-hole samples during the equipment commissioning phase.

[0071] The target pressure for the j-th level positive inflation of the i-th detection channel is determined by the following formula: in, The target pressure for the j-th positive inflation stage of the i-th detection channel is expressed in MPa; j represents the positive inflation stage. The positive inflation starting pressure for the i-th detection channel is expressed in MPa. This represents the pressure step for the i-th detection channel, in MPa. and The results are derived from the PLC control alarm system's retrieval of sealing reference data and reverse release response data.

[0072] During graded positive inflation, the PLC control alarm system, based on the determined positive inflation starting pressure and pressure steps, gradually changes the control voltage or current signal input to the electro-proportional valve according to the holding time of each stage. This causes the inflation pressure in the detection channel to rise precisely in a step-like manner, thereby avoiding damage to the original obstruction state of the tiny orifice by a single large pressure impact.

[0073] For example, the pressure recovery time of the first detection channel is 0.115s, and the pressure rebound ratio is 0.70, both within the normal range calibrated by the equipment. The PLC control alarm system sets the forward inflation starting pressure to 0.060MPa and the pressure step to 0.040MPa, forming four levels of forward inflation: 0.060MPa, 0.100MPa, 0.140MPa, and 0.180MPa. The pressure recovery time of the second detection channel is 0.260s and includes a pressure recovery delay indicator. The PLC control alarm system adjusts the forward inflation starting pressure to 0.040MPa and the pressure step to 0.030MPa, creating a gentler forward pressure loading process to avoid sudden changes in forward pressure that could re-press burrs, oil films, or debris.

[0074] S420. Collect and calculate the pressure characteristics during the staged forward inflation process: At the beginning of each stage of forward inflation, the PLC control alarm system activates the forward inflation sampling window of the corresponding detection channel. The forward inflation sampling window refers to the continuous sampling time period from the opening time of the forward inflation valve of that stage to the end time of the pressure holding of that stage.

[0075] The intelligent sensor and digital pressure display device continuously collect pressure values ​​within the forward inflation sampling window. The collected data includes at least the starting pressure of the inflation stage, the ending pressure of the inflation rise phase of the stage, the pressure sampling time sequence, the local high point pressure, the local low point pressure, and the ending pressure of the holding pressure stage. The pressure values ​​are derived from the pressure sampling data of the first or second detection channel, and the timestamps are derived from the sampling clock of the PLC control alarm system.

[0076] The pressure rise slope of the j-th stage of positive inflation in the i-th detection channel is calculated using the following formula: in, The pressure rise slope of the j-th stage of positive inflation in the i-th detection channel is expressed in MPa / s. The pressure at the start of the j-th stage of positive inflation in the i-th detection channel, in MPa; The pressure at the end of the j-th stage of the positive inflation rising phase of the i-th detection channel, in MPa; The time of start of positive inflation at level j for the i-th detection channel is expressed in seconds. The time of the end of the j-th stage of the forward inflation rise in the i-th detection channel is expressed in seconds. The pressure rise slope is used to characterize the pressure build-up rate after the forward gas enters the detection channel.

[0077] The secondary discharge step amplitude is calculated using the following formula: in, The amplitude of the secondary discharge step of the i-th detection channel is expressed in MPa. The pressure at the local high point before the sudden pressure drop in the i-th detection channel is expressed in MPa. The stable low pressure after the sudden pressure drop in the i-th detection channel is expressed in MPa. and All data originated from pressure sampling sequences within the forward inflation sampling window.

[0078] The secondary venting step refers to a pressure change segment where the pressure initially rises with forward inflation, then suddenly drops due to the opening of burrs, oil films, or debris at the micro-orifices by the airflow, and subsequently enters a new venting equilibrium state. The pressure delay abrupt change point is the sampling moment when the pressure transitions from a local high point to the sudden drop segment, and the sudden drop delay time is the time difference between the start of forward inflation at the corresponding stage and the pressure delay abrupt change point.

[0079] For example, in the first detection channel during the second stage of positive inflation, the pressure rises from 0.060 MPa to 0.100 MPa in 0.050 s, resulting in a pressure rise slope of 0.800 MPa / s. Subsequently, the pressure abruptly drops from 0.118 MPa to 0.086 MPa at 0.120 s and remains near 0.086 MPa. The pressure delay abrupt change point is 0.120 s, and the secondary venting step amplitude is 0.032 MPa. Therefore, the variable shielding orifice can be quantitatively identified through the pressure delay abrupt change point and the secondary venting step in the pressure sampling sequence.

[0080] S430, Combining to form the pressure response signatures of the first and second products: The PLC control alarm system combines the first sealing reference data obtained in S230, the first reverse release response data obtained in S330, and the first detection channel forward inflation pressure feature obtained in S420 to form the pressure response signature of the first product; and combines the second sealing reference data obtained in S230, the second reverse release response data obtained in S330, and the second detection channel forward inflation pressure feature obtained in S420 to form the pressure response signature of the second product.

[0081] Pressure response signature refers to a set of data characterizing the pressure behavior of a corresponding product during the continuous testing process of "sealing confirmation, reverse release, and graded forward inflation." It includes at least the product test serial number, test channel number, sealing reference data, reverse release pulse intensity, pressure recovery time, pressure rebound ratio, graded forward inflation parameters, pressure rise slope at each stage, pressure delay abrupt change point, secondary release step amplitude, residual pressure at each stage, residual pressure at the final stage, and anomaly markers. Residual pressure at each stage refers to the pressure value collected at the end of each stage of forward inflation holding; residual pressure at the final stage refers to the pressure value collected at the end of the last stage of forward inflation holding.

[0082] The residual pressure deviation of the final stage voltage stabilizer is calculated using the following formula: in, The residual voltage deviation of the final stage voltage regulator in the i-th detection channel is expressed in MPa. The stable residual pressure collected by the i-th detection channel at the end of the final stage of positive inflation and pressure holding is expressed in MPa. The reference stabilized residual pressure is obtained by the i-th test channel when calibrating a qualified through-hole sample, in MPa. Data derived from pressure sampling of the current product. It comes from calibration data during the equipment commissioning phase.

[0083] For example, the pressure response signature of the first product includes the first detection channel number, reverse release pulse intensity of 0.007 MPa·s, pressure recovery time of 0.115 s, pressure rebound ratio of 0.70, second-stage pressure rise slope of 0.800 MPa / s, pressure delay abrupt change point of 0.120 s, secondary venting step amplitude of 0.032 MPa, and final stage stabilization residual pressure of 0.086 MPa.

[0084] Since the pressure response signature includes both the recovery behavior after reverse release and the sudden release behavior during forward inflation, S520 can determine that the first product has a variable blocking orifice. If the pressure response signature of the second product shows that the pressure at each stage continuously increases, no secondary venting step occurs, and the final stage stabilizing residual pressure is higher than the reference stabilizing residual pressure, then S510 can determine that the second product has a blind orifice or severe blockage.

[0085] The pressure response signatures of the first product and the second product are output to S510-S530 to complete the determination of the existence of micropores, binding of test results, and quality traceability.

[0086] S5 specifically includes the following sub-steps: S510. Identify the presence status of micro-holes and continuous high pressure status based on pressure response signatures: The PLC control alarm system calls the first product pressure response signature and the second product pressure response signature generated in S430, and compares them according to the preset micro-hole presence determination rules.

[0087] The preset micro-hole existence determination rules refer to the set of determination rules formed after testing qualified through-hole samples, blind hole samples, severely blocked hole samples, and variable obstruction hole samples under the same material loading mechanism, the same hollow inflatable punch, the same rubber sealing ring specifications, and the same air source during the equipment adjustment phase. These rules include at least the reference stabilizing residual pressure for qualified through-holes, the allowable stabilizing residual pressure deviation, the high-pressure determination threshold, the secondary venting step threshold, and the sudden drop delay time threshold. The above calibration data is written into the PLC control alarm system, and the calibration value of the corresponding detection channel is retrieved based on the product channel correspondence during each test.

[0088] The PLC control alarm system prioritizes determining whether the pressure response signature exhibits stable discharge characteristics or continuous high-pressure characteristics. Stable discharge characteristics refer to continuous discharge occurring during the staged forward inflation process of the corresponding detection channel, with the final stage stabilized residual pressure approaching the reference stabilized residual pressure of a qualified through-hole sample, and no sustained high pressure is observed. Continuous high-pressure characteristics refer to a continuous increase in pressure during each stage of forward inflation of the corresponding detection channel, with the final stage stabilized residual pressure exceeding the high-pressure judgment threshold, and no effective secondary discharge step is formed. The final stage stabilized residual pressure deviation is calculated according to the method in S430.

[0089] For example, the reference stabilized residual pressure for the qualified through-hole in the first detection channel is 0.085 MPa, and the allowable deviation of the final stage stabilized residual pressure is 0.015 MPa. Currently, the final stage stabilized residual pressure of the first product is 0.092 MPa, so the deviation is 0.007 MPa. Simultaneously, the pressure response signature of the first product does not show sustained high pressure or abnormal pressure drops. The PLC control alarm system determines that the first product has stable discharge characteristics and marks it as having a small hole. If the final stage stabilized residual pressure of the second product is 0.160 MPa, exceeding the preset high-pressure threshold of 0.130 MPa, and the pressure at each stage continues to rise without secondary discharge steps, the PLC control alarm system determines that the second product has a blind hole or severe blockage.

[0090] S520. Identifying Variable Obstruction Orifices Based on Secondary Discharge Characteristics: If S510 does not directly determine the corresponding product as having stable discharge or continuous high pressure, the PLC control alarm system continues to call upon the product's reverse release response data and graded forward inflation pressure characteristics to determine whether the corresponding product has variable obstruction orifices. Variable obstruction orifices refer to orifices where a micro-orifice has been formed, but the orifice opening is temporarily obstructed by burrs, oil films, or debris, and its opening and closing changes with the reverse release pulse, forward airflow direction, or pressure state.

[0091] This state differs from both stable through holes and blind holes. Its typical characteristics are: after reverse release, there is at least one of the following: pressure recovery delay, abnormal pressure rebound ratio, or abnormal release marker; during staged forward inflation, high pressure is maintained first, followed by a sudden pressure drop, and then enters a stable release range after the sudden drop.

[0092] The effectiveness of secondary venting is determined by the following formula: in, The result of the secondary discharge effectiveness determination for the i-th detection channel; The amplitude of the secondary discharge step of the i-th detection channel is expressed in MPa. The preset threshold value for the secondary discharge step is in MPa. The delay time from the start of positive inflation of the corresponding level to the occurrence of a sudden pressure drop in the i-th detection channel is expressed in seconds. The upper limit of the preset sudden drop delay time is in seconds; The stable low pressure after the sudden pressure drop in the i-th detection channel is expressed in MPa. This refers to the upper limit of the stable discharge pressure after the variable shielding orifice is released, expressed in MPa. The above... , and The results are derived from the comparative calibration of variable obstruction hole samples and qualified through hole samples during the equipment commissioning phase. , and The positive inflation pressure sampling sequence was obtained from the S420.

[0093] For example, during the second stage of positive inflation in the first detection channel, the pressure first rises to 0.118 MPa and remains there for 0.120 seconds, then suddenly drops to 0.086 MPa, with a secondary discharge step amplitude of 0.032 MPa. If the preset secondary discharge step amplitude threshold is 0.020 MPa, the preset upper limit of the sudden drop delay time is 0.300 seconds, and the upper limit of the stable discharge pressure after the variable shielding orifice releases is 0.100 MPa, then this secondary discharge characteristic is valid. If the channel also records a pressure recovery delay mark in S330, the PLC control alarm system determines that the corresponding product has a variable shielding orifice. If the pressure drop amplitude is only 0.006 MPa, which is lower than the preset secondary discharge step amplitude threshold, then this change is considered as sampling fluctuation or normal discharge fluctuation and is not used as a basis for determining a variable shielding orifice.

[0094] S530: Binding Detection Results and Outputting Production Control and Traceability Data: Based on the product channel correspondence formed in S110, the PLC control alarm system binds the detection results obtained in S510 and S520 to the first and second products, respectively. The detection result refers to the orifice status category formed after the corresponding product undergoes pressure response signature determination, including at least the presence of micro-holes, blind holes or severely blocked holes, and variable obstruction holes.

[0095] To avoid confusion of results during dual-channel synchronous testing, the test results are stored using the product test serial number, loading mechanism number, test position number, and test channel number as indexes, and are output together with the sealing reference data, reverse release response data, and pressure response signature.

[0096] The test result binding is represented by the following formula: in, This represents the test result for the i-th product. Let i be the product inspection serial number of the i-th product; Let be the detection channel number corresponding to the i-th product; The pressure response signature for the i-th product; f is the preset micro-hole existence determination rule in the PLC control alarm system. and The product channel correspondence is derived from S110. The pressure response signature is derived from S430.

[0097] For example, in S110, the first product's inspection serial number is recorded as A001 and bound to the first inspection channel, and the second product's inspection serial number is recorded as A002 and bound to the second inspection channel. If the pressure response signature of A001 meets the condition for a variable obstruction hole, and the pressure response signature of A002 meets the characteristic for stable discharge, the PLC control alarm system marks A001 as a variable obstruction hole and outputs an isolation re-inspection command, and marks A002 as a micro-hole and outputs a release command. If any product is determined to be a blind hole or a severely blocked hole, the PLC control alarm system outputs a rejection alarm or a shutdown alarm, and displays the corresponding product inspection serial number, inspection channel number, and abnormality category on the information display screen.

[0098] The final output traceability data includes at least the product inspection serial number, material loading mechanism number, inspection channel number, judgment time, inspection result, sealing reference data number, reverse release response data number, pressure response signature number, and PLC control action, which are used for subsequent quality traceability and batch anomaly analysis.

[0099] Example 2: Figure 2 As shown, this embodiment provides a dual-channel micropore presence detection system, including: The positioning and pressing module is used to position the first product and the second product at the first detection position and the second detection position of the loading mechanism, respectively, to establish the product channel correspondence between the first product and the first detection channel and the second product and the second detection channel, and to collect pressing displacement, pressing pressure and positioning signal through intelligent sensors to generate dual-channel positioning confirmation information. The sealing reference module is used to drive the dual-channel inflation assembly to rise according to the dual-channel positioning confirmation information, so that the first hollow inflation punch and the second hollow inflation punch form an outer peripheral seal with the corresponding product ball socket, and collect sealing status data through short-term low-pressure test inflation to form sealing reference data and effective sealing detection air path. The reverse release module is used to apply controlled reverse release pulses to the first and second detection channels based on the effective seal detection gas path, collect pressure recovery data, and generate reverse release response data; The graded inflation acquisition module is used to determine the graded forward inflation parameters based on the reverse release response data, perform graded forward inflation on the first and second detection channels, and acquire the pressure rise slope, pressure delay abrupt change point, secondary release step amplitude and final stage stabilization residual pressure to form a pressure response signature. The determination and traceability module is used to compare the pressure response signature with the preset micro-hole existence determination rules, determine the corresponding product as having one of the following detection results: micro-hole presence, blind hole, severely blocked hole, or variable obstruction hole, and output production control and traceability data according to the product channel correspondence.

[0100] It should be noted that the aforementioned positioning and pressing module, sealing reference module, reverse release module, graded inflation and acquisition module, and judgment and traceability module are physically achieved through the coordinated operation of the PLC control alarm system, RFID reader or barcode scanner, high-precision displacement sensor, high-frequency digital pressure sensor, digital pressure display device, electro-proportional valve, high-frequency solenoid valve, and pneumatic actuators (such as the aforementioned pneumatic pressing mechanism and dual-channel inflation assembly) within this system. Control commands and data communication between the various hardware devices are accomplished via an industrial communication bus, thereby ensuring the precise execution of high-frequency pressure acquisition and millisecond-level pneumatic actions.

[0101] All the above formulas are performed using dimensionless numerical calculations; the relevant formulas are based on empirical models that approximate the real situation, obtained through extensive data collection and software simulation fitting. The preset parameters and thresholds involved in the formulas can be conventionally set and adjusted by those skilled in the art according to the physical constraints of the actual application scenario.

[0102] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0103] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0104] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A dual channel micro-hole existence detection method, characterized in that, Includes the following steps: S1. Position the first product and the second product at the first detection position and the second detection position of the loading mechanism, establish the product channel correspondence between the first product and the first detection channel, and between the second product and the second detection channel, collect the pressing status data, and generate dual-channel positioning confirmation information; S2. Drive the dual-channel inflation assembly to rise according to the dual-channel positioning confirmation information, so that the first hollow inflation punch, the second hollow inflation punch and the corresponding product ball socket form an outer circumferential seal, perform short-term low-pressure test inflation, collect sealing status data, and form sealing reference data. S3. After the sealing detection conditions are met in the first and second detection channels, a controlled reverse release pulse is applied based on the first and second effective sealing detection gas paths, pressure recovery data is collected, and reverse release response data is formed. S4. Determine the graded forward inflation parameters based on the reverse release response data, perform graded forward inflation on the first and second detection channels, and collect the pressure rise slope, pressure delay abrupt change point, secondary release step amplitude and final stage stabilization residual pressure to form a pressure response signature. S5. Compare the pressure response signature with the preset micro-hole existence determination rules, determine the corresponding product as having one of the following detection results: micro-hole existence, blind hole, severely blocked hole, or variable obstruction hole, and output production control and traceability data according to the product channel correspondence.

2. The dual channel micro-hole existence detection method according to claim 1, wherein, S1 specifically includes: Place the first product in the first detection position and the second product in the second detection position. Read the material loading mechanism number, detection position number, detection channel number and product detection sequence number. Establish the product channel correspondence between the first product and the first detection channel and the second product and the second detection channel. Confirm the placement direction based on the planar deviation of the ball socket center relative to the channel axis projection point. After the product channel correspondence is valid, the upper pneumatic pressing mechanism is controlled to press down. The intelligent sensor collects the pressing displacement, pressing pressure and positioning signal to form pressing status data. The stable positioning state is determined based on the plane deviation, the material displacement deviation, the material holding pressure, and the holding time. When the conditions are met, dual-channel positioning confirmation information is generated.

3. The dual channel micro-hole existence detection method according to claim 1, wherein, S2 specifically includes: After receiving the dual-channel positioning confirmation information, the dual-channel inflation assembly is driven to rise, so that the first hollow inflation punch enters the first product ball socket and the second hollow inflation punch enters the second product ball socket, and an outer circumferential seal is formed by the rubber sealing ring. The sealing fit status is confirmed based on the punch positioning signal, the rising stroke and the rubber sealing ring compression rate. A short-term low-pressure test inflation is performed on the first and second detection channels to collect data on the punch's position, test inflation pressure, test pressure holding end pressure, and test pressure decay rate, thus forming the first and second sealing reference data.

4. The dual channel micro-hole existence detection method according to claim 3, characterized in that, Also includes: Based on the sealing reference data, determine whether each detection channel meets the sealing detection conditions. If it does, output the first effective sealing detection gas path and the second effective sealing detection gas path.

5. The dual channel micro-hole existence detection method according to claim 1, wherein, S3 specifically includes: After the first effective seal detection gas path and the second effective seal detection gas path are established, the control reverse release branch is connected to the first detection channel and the second detection channel respectively, and a controlled reverse release pulse is applied according to the trial inflation pressure, the target release pressure, the release duration and the number of releases. After the pulse ends, a pressure recovery sampling window is activated. The pressure at the end of the pulse, the pressure sequence during the recovery process, the arrival time of the target pressure, and the pressure at the end of the window are collected by intelligent sensors and digital pressure display devices to obtain pressure recovery data. The pressure recovery time, residual pressure after recovery, pressure rebound amplitude, and pressure rebound ratio are extracted from the pressure recovery data to form the first reverse release response data and the second reverse release response data.

6. The dual channel micro-hole existence detection method according to claim 1, wherein, S4 specifically includes: Based on the first reverse release response data and the second reverse release response data, the graded forward inflation parameters of the first detection channel and the second detection channel are determined respectively. The graded forward inflation parameters include forward inflation starting pressure, pressure step, number of inflation stages and holding time for each stage. According to the graded positive inflation parameters, the first and second detection channels are positively inflated from low to high. The pressure sampling data in the positive inflation sampling window is collected by intelligent sensors and digital pressure display devices, and the pressure rise slope, pressure delay abrupt change point, secondary release step amplitude and residual pressure at each level are extracted.

7. The dual channel micro-hole existence detection method according to claim 6, wherein, Also includes: The sealing reference data, reverse release response data, and forward inflation pressure characteristics are combined to form the pressure response signatures of the first and second products.

8. The dual-channel micro-orifice presence detection method according to claim 1, characterized in that, S5 specifically includes: The pressure response signatures of the first and second products are called, and the stable discharge characteristics and continuous high pressure characteristics are identified according to the preset micro-hole existence judgment rules. Products with stable discharge characteristics are judged to have micro-holes, and products with continuous high pressure characteristics and no effective secondary discharge steps are judged to be blind holes or severely blocked holes. For products that are not directly determined, reverse release response data and graded positive inflation pressure characteristics are used to identify variable shielding holes based on the amplitude of the secondary release step, the sudden drop delay time, and the stable low point pressure after the sudden drop. Based on the product channel correspondence, the test results are bound together, and release, rejection alarm, shutdown alarm or isolation re-inspection instructions are output, and traceability data is generated.

9. A dual-channel micro-orifice presence detection system, employing the dual-channel micro-orifice presence detection method according to any one of claims 1 to 8, characterized in that, include: The positioning and pressing module is used to position the first product and the second product at the first detection position and the second detection position of the loading mechanism, respectively. The sealing reference module is used to drive the dual-channel inflation assembly to rise according to the dual-channel positioning confirmation information, so that the first hollow inflation punch and the second hollow inflation punch respectively form an outer peripheral seal with the corresponding product ball socket; The reverse release module is used to apply controlled reverse release pulses to the first and second detection channels based on the effective seal detection gas path; The graded inflation acquisition module is used to determine the graded forward inflation parameters based on the reverse release response data, and to perform graded forward inflation on the first detection channel and the second detection channel; The determination and traceability module is used to compare the pressure response signature with the preset micro-hole existence determination rules to determine whether the corresponding product has one of the following detection results: micro-hole presence, blind hole or severely blocked hole, or variable shielding hole.

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