Full-automatic loading and unloading detection and sorting equipment for a supporting wheel

Abstract

The application discloses a full-automatic loading and unloading detection and sorting equipment for supporting wheels, and relates to the technical field of flaw detection equipment.The application comprises a loading mechanism, a flaw detector assembly, a demagnetization mechanism assembly, a magnetization mechanical arm assembly, a unloading conveying mechanism and a unloading mechanical arm assembly, wherein each mechanism is arranged in a straight line, and a complete system is formed by cooperating with a safety fence and a darkroom assembly.The loading mechanism and the demagnetization mechanism adopt a bidirectional screw rod to realize adjustable spacing, the magnetization mechanical arm adopts a three-station synchronous grabbing and transferring, the flaw detection link integrates magnetic powder flaw detection and AI visual identification, the demagnetization adopts an adjustable alternating current remote method, and the unloading is automatically sorted according to the detection results to obtain qualified products and defective products.The application realizes full-process automation of loading, flaw detection, demagnetization and sorting of supporting wheels, is suitable for multiple specifications of workpieces, is accurate and stable in detection, is efficient and safe in operation, and can meet the production requirements of batch intelligent detection of supporting wheels.

Description

Technical Field

[0001] This invention relates to the field of flaw detection equipment technology, specifically to a fully automatic loading, unloading, inspection, and sorting device for support rollers. Background Technology

[0002] Track rollers are core load-bearing components of the walking system of construction machinery. Surface and near-surface cracks on these rollers can directly lead to equipment malfunctions or even safety accidents, therefore non-destructive testing (NDT) is essential. Currently, the main technical bottlenecks in track roller NDT within the industry are as follows:

[0003] Low level of automation: Traditional manual flaw detection requires 2-3 people to complete the loading, flipping, inspection and unloading, which is labor-intensive, has low productivity, and there is a risk of mechanical injury from manual handling;

[0004] Poor consistency in testing: Manual testing is affected by fatigue, experience, and differences in fluorescent lamp illumination, resulting in a high rate of missed detections and a high risk of defective products leaving the site.

[0005] Insufficient flexibility and adaptability: Existing equipment can only be adapted to a single specification of support roller. Changing the machine model requires disassembling and changing the tooling, and the single changeover time exceeds 30 minutes, which cannot meet the needs of multi-variety mixed production line.

[0006] Therefore, it is necessary to develop a fully automatic loading, unloading, detection, and sorting equipment for support rollers that is universal across multiple models, highly safe, and fully automated throughout the entire process. Summary of the Invention

[0007] To solve the above problems, the present invention adopts the following technical solution.

[0008] A fully automatic support roller loading, unloading, inspection, and sorting device, characterized in that it includes:

[0009] The feeding mechanism is used to transport the support rollers to be tested;

[0010] The flaw detector assembly is used for flaw detection of support rollers;

[0011] The demagnetizing mechanism assembly is used to demagnetize the support rollers after the testing is completed;

[0012] The magnetized manipulator assembly is used to grasp support rollers and transfer them between the feeding mechanism, the flaw detector assembly, and the demagnetizing mechanism assembly.

[0013] Two feeding conveyor mechanisms are used to transport qualified product pallets and defective product pallets, respectively;

[0014] The unloading robot assembly is used to grab the support rollers from the demagnetizing mechanism assembly and transfer them to one of the unloading conveyor mechanisms;

[0015] The feeding mechanism, flaw detector assembly, and demagnetizing mechanism assembly are arranged in a straight line, and the conveying direction of the feeding mechanism is perpendicular to the conveying direction of the unloading conveying mechanism.

[0016] Preferably, the system also includes a safety guardrail assembly for enclosing the demagnetizing mechanism assembly, the magnetizing manipulator assembly, and the two unloading conveying mechanisms. The safety guardrail assembly includes an entrance / exit safety gate and two lifting and opening gates, which are respectively located above the discharge ends of the two unloading conveying mechanisms.

[0017] Preferably, the system also includes a darkroom assembly, which encloses the feeding mechanism, flaw detector assembly, demagnetizing mechanism assembly, and magnetizing robot assembly. The darkroom assembly has a feed inlet for the feeding mechanism and a discharge outlet for the demagnetizing mechanism assembly on its sidewalls.

[0018] Preferably, the feeding mechanism includes a base, with two guide rods arranged parallel to each other on the upper part of the base. Guide rod supports are provided at both ends of the guide rods. Screws are provided at both ends of the base perpendicular to the guide rods. The screws are threaded to the bottom of the guide rod supports on the same side. The threads of the left and right halves of the screws are in opposite directions. The threads of the threaded holes on the guide rod supports on the same guide rod are in the same direction. A sprocket is provided at one end of both screws on the same side. The two sprockets are connected by a chain. A handwheel is provided at one end of one of the screws.

[0019] Preferably, the demagnetizing mechanism assembly includes a base two, with two guide rods two parallel to each other on the upper part of the base two. Guide rod supports are respectively provided at both ends of the guide rods two. Screws two are provided perpendicular to the guide rods two at both ends of the base two. The screws two are threadedly connected to the bottom of the guide rod supports on the same side. The threads of the left and right halves of the screws two have opposite directions. The threads of the threaded holes on the guide rod supports on the same guide rod two have the same direction. Sprockets two are provided at the ends of the two screws two on the same side. The two sprockets two are connected by a chain. A handwheel is provided at one end of one of the screws two. The demagnetizing mechanism is arranged across the ends of the two guide rods two near the flaw detector assembly.

[0020] Preferably, the magnetizing manipulator assembly includes a support frame, a support beam at the top of the support frame, a horizontal moving mechanism, a lifting mechanism, and a mounting bracket at the lower end of the lifting mechanism. Three gripping mechanisms are mounted on the mounting bracket along the moving direction of the horizontal moving mechanism, and the spacing between the three gripping mechanisms is the same as the distance between the end of the feeding mechanism, the inspection station of the flaw detector assembly, and the feeding end of the demagnetizing mechanism assembly.

[0021] Preferably, the horizontal moving mechanism includes a mounting plate, which is slidably mounted on the support beam. A telescopic mechanism is mounted on the mounting plate, and its extended end is connected to the support frame. The telescopic direction of the telescopic mechanism is the same as the arrangement direction of the feeding mechanism, the flaw detector assembly, and the demagnetizing mechanism assembly.

[0022] The lifting mechanism includes a vertical rail, a connecting frame slidably mounted on the vertical rail, a toothed plate on one side of the connecting frame, a drive motor mounted on a mounting plate, and a drive gear at the output end of the drive motor meshing with the toothed plate.

[0023] The gripping mechanism includes two oppositely arranged booms, which are slidably mounted on the bottom of the mounting bracket. The booms are L-shaped. The top of the mounting bracket is provided with telescopic mechanisms two corresponding to the booms. The extended ends of the telescopic mechanisms two are oppositely arranged and connected to the corresponding booms.

[0024] Preferably, the unloading robot assembly includes a support frame two. The top of the support frame two is provided with a guide rail one perpendicular to the conveying direction of the unloading conveying mechanism. A horizontal moving mechanism two is provided on the guide rail one. The horizontal moving mechanism two includes a frame one, which slides on the guide rail one. A drive component one is also provided on the frame one. Guide rail two is horizontally provided on the two sides of the top of the frame one. A horizontal moving mechanism three is provided on the guide rail two. The guide rail two is perpendicular to the guide rail one. The horizontal moving mechanism three includes a mounting plate two, which slides on the two guide rail two. A lifting mechanism two is provided on the mounting plate two. A gripping mechanism two is provided at the bottom of the lifting mechanism two.

[0025] Preferably, the drive assembly one includes a drive motor two, which is disposed on the top of the frame one. The output end of the drive motor two is provided with a drive pulley. A toothed plate two is disposed parallel to the bottom of the guide rail one. Rotary shaft seats one is disposed at both ends of the bottom of the frame one, and a connecting shaft is disposed between the two rotary shaft seats one. Driven gears one are disposed at both ends of the connecting shaft, meshing with the toothed plate two. A driven pulley is also disposed at one end of the connecting shaft. The drive pulley and the driven pulley are connected by a belt drive.

[0026] A toothed plate three is provided parallel to the side of the guide rail two. A drive motor three is provided on the top side of the mounting plate two. A drive gear two is provided at the output end of the drive motor three. The drive gear two meshes with the toothed plate three.

[0027] A guide frame is vertically mounted on the mounting plate 2, and a column is vertically slidably mounted on the guide frame. A toothed plate 4 is vertically mounted on the column. A rotating shaft seat 2 is also mounted on the mounting plate 2, and a drive gear 3 is rotatably mounted on the rotating shaft seat 2. The drive gear 3 meshes with the toothed plate 4. A drive motor 4 is also mounted on the mounting plate 2, and the output end of the drive motor 4 is connected to the rotating shaft.

[0028] The second gripping mechanism is a horizontally arranged pneumatic internal gripper.

[0029] Compared with the prior art, the beneficial effects of this invention are as follows:

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] This invention employs a special screw design with the left half rotating left and the right half rotating right in the feeding and demagnetizing mechanisms. Combined with synchronous transmission of sprockets and chains, the guide rod spacing can be infinitely adjusted by turning the handwheel without disassembling any tooling. It can quickly adapt to various specifications of support rollers, significantly shortening the machine changeover time.

[0032] This invention utilizes a magnetized robotic arm assembly with a synchronous design of three equally spaced gripping mechanisms. In a single cycle, it can simultaneously complete three actions: loading the part to be inspected, transferring the inspected part to demagnetize, and transferring the demagnetized part to unload. This significantly shortens the transfer time and greatly improves production efficiency.

[0033] This invention combines magnetic particle inspection technology and AI machine vision recognition technology. It uses multi-angle high-definition industrial cameras to acquire images and uses deep learning algorithms to automatically identify the location, length and depth of cracks. It has high detection sensitivity and high recognition accuracy. The system automatically stores all detection images and results and supports data export and full-process traceability.

[0034] This invention uses a robotic arm to automatically sort qualified and defective products based on the detection signals sent by the flaw detector assembly. The sorting accuracy is high and mixing of materials is effectively avoided. Attached Figure Description

[0035] Figure 1 This is a perspective view of the overall structure of the present invention;

[0036] Figure 2 This is a top view of the overall structure of the present invention;

[0037] Figure 3 This is a perspective view of the feeding mechanism of the present invention;

[0038] Figure 4 This is a bottom view of the feeding mechanism of the present invention;

[0039] Figure 5 This is a three-dimensional view of the magnetized manipulator assembly of the present invention;

[0040] Figure 6 This is a top view of the magnetized manipulator assembly of the present invention;

[0041] Figure 7 This is a side view of the magnetized manipulator assembly of the present invention;

[0042] Figure 8 This is a schematic diagram of the material feeding and conveying mechanism of the present invention;

[0043] Figure 9 This is a three-dimensional view of the material unloading robot of the present invention;

[0044] Figure 10 This is a partial structural diagram of the unloading robot assembly of the present invention.

[0045] Explanation of reference numerals in the attached figures:

[0046] 1. Feeding mechanism: 101. Base 1, 102. Guide rod 1, 103. Guide rod support, 104. Screw 1, 105. Sprocket 1; 2. Flaw detector assembly; 3. Demagnetizing mechanism assembly: 301. Base 2, 302. Guide rod 2, 303. Guide rod support, 304. Screw 2, 305. Sprocket 2, 306. Demagnetizing mechanism; 4. Magnetizing robot assembly: 401. Support frame 1, 402. Support beam, 403. Mounting bracket, 404. Mounting plate 1, 405. Telescopic mechanism 1, 406. Vertical rail 1, 407. Connecting frame 1, 408. Tooth plate 1, 409. Drive motor 1, 410. Drive gear 1, 411. Boom, 412. Telescopic mechanism 2; 5. Unloading conveying mechanism; 6. Unloading robot assembly, 601. Bracket 2, 602. Guide rail 1, 603. Frame 1, 604. Guide rail 2, 605. Mounting plate 2, 606. Drive motor 2, 607. Drive pulley, 608. Gear plate 2, 609. Rotary shaft seat 1, 610. Connecting shaft, 611. Driven gear 1, 612. Driven pulley, 613. Gear plate 3, 614. Drive motor 3, 615. Drive gear 2, 616. Guide frame, 617. Column, 618. Gear plate 4, 619. Rotary shaft seat 2, 620. Drive gear 3, 621. Drive motor 4, 622. Pneumatic internal chuck; 8. Safety guardrail assembly, 801. Access safety door, 802. Lifting and opening door; 9. Darkroom assembly. Detailed Implementation

[0047] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0048] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0049] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0050] Example

[0051] like Figure 1-10 As shown, this invention discloses a fully automatic loading, unloading, inspection, and sorting device for support rollers, comprising a loading mechanism 1, a flaw detector assembly 2, a demagnetizing mechanism assembly 3, a magnetizing robot assembly 4, two unloading conveying mechanisms 5, an unloading robot assembly 6, a safety guardrail assembly 8, and a darkroom assembly 9. The loading mechanism 1, the flaw detector assembly 2, and the demagnetizing mechanism assembly 3 are arranged in a straight line, and the conveying direction of the loading mechanism 1 is perpendicular to the conveying direction of the unloading conveying mechanism 5.

[0052] In this embodiment, the feeding mechanism 1 includes a base 101, on which two guide rods 102 for supporting and conveying the support rollers are arranged parallel to each other. Guide rod supports 103 are fixedly connected to both ends of the guide rods 102. Screws 104 are rotatably mounted on both ends of the base 101 perpendicular to the guide rods 102. The left half of the screw 104 has a left-hand thread, and the right half has a right-hand thread. The two guide rod supports 103 on the same guide rod 102 are respectively threaded to the left and right sections of the screw 104, and the threaded holes on the two guide rod supports 103 have the same direction of rotation. A sprocket 105 is fixedly mounted on the same side of both screws 104, and the two sprockets 105 are connected by a transmission chain. A handwheel is fixedly mounted on the outer end of one of the screws 104. When the handwheel is turned, the two screws 104 rotate synchronously, driving the guide rod supports 103 on both sides to move equidistantly to the middle or both sides, thereby realizing stepless adjustment of the distance between the two guide rods 102 to adapt to support rollers of different lengths.

[0053] In this embodiment, the structure of the demagnetizing mechanism assembly 3 is basically the same as that of the feeding mechanism 1, including a base 301. Two guide rods 302 are arranged parallel to each other on the upper part of the base 301, and guide rod supports 303 are respectively provided at both ends of the guide rods 302. Screws 304 are provided at both ends of the base 301 perpendicular to the guide rods 302. The threads of the left and right halves of the screws 304 have opposite directions. The guide rod supports 303 on the same guide rod 302 are respectively connected to the left and right threads of the screws 304. Sprockets 305 are provided at the ends of the two screws 304 on the same side. The two sprockets 305 are connected by a chain. A handwheel is provided at one end of one of the screws 304. A demagnetizing mechanism 306 is fixedly installed across the two guide rods 302 near the flaw detector assembly 2. A demagnetizing coil is provided inside the demagnetizing mechanism 306.

[0054] In this embodiment, the magnetized manipulator assembly 4 includes a support frame 401 fixed to the ground, with a horizontal support beam 402 fixedly mounted on the top of the support frame 401. A horizontal moving mechanism 402 is slidably mounted on the support beam 402, and the horizontal moving mechanism 404 includes a mounting plate 404, which is slidably connected to the support beam 402 via a slider. A telescopic mechanism 405, preferably a cylinder telescopic rod, is fixedly mounted on the mounting plate 404. The extended end of the telescopic mechanism 405 is fixedly connected to the end of the support frame 401, and the telescopic direction of the telescopic mechanism 405 is the same as the arrangement direction of the feeding mechanism 1, the flaw detector assembly 2, and the demagnetizing mechanism assembly 3. A lifting mechanism 406 is fixedly mounted on the mounting plate 404, and the lifting mechanism 407 includes a vertically arranged rail 406, with a connecting frame 407 slidably connected to the rail 406 via a slider. A toothed plate 408 is fixedly mounted on one side of the connecting frame 407. A drive motor 409 is fixedly mounted on the mounting plate 404. A drive gear 410 is fixedly mounted on the output end of the drive motor 409, and the drive gear 410 meshes with the toothed plate 408. When the drive motor 409 rotates, it drives the connecting frame 407 to move up and down along the vertical rail 406 through gear and rack transmission. A horizontal mounting bracket 403 is fixedly mounted on the lower end of the connecting frame 407. Three gripping mechanisms are evenly spaced on the mounting bracket 403 along the moving direction of the horizontal moving mechanism. The spacing between the three gripping mechanisms is exactly the same as the center distance between the end of the feeding mechanism 1, the inspection station of the flaw detector assembly 2, and the feeding end of the demagnetizing mechanism assembly 3. Each gripping mechanism includes two L-shaped booms 411 arranged opposite each other. The booms 411 are slidably mounted on the bottom of the mounting bracket 403 by a slider. A telescopic mechanism 412 is fixedly installed on the top of the mounting bracket 403 for each boom 411, preferably a cylinder telescopic rod. The extended ends of the telescopic mechanism 412 are arranged opposite each other and fixedly connected to the corresponding boom 411. When the telescopic mechanism 412 extends or retracts, it drives the two booms 411 to move towards or away from each other, thereby gripping and releasing the support roller.

[0055] In this embodiment, the unloading robot assembly 6 includes a second bracket 601 fixed on the ground. A guide rail 602 perpendicular to the conveying direction of the unloading conveying mechanism 5 is fixedly mounted on the top of the second bracket 601. A second horizontal moving mechanism is slidably mounted on the first guide rail 602. The second horizontal moving mechanism includes a first frame 603, which is slidably connected to the first guide rail 602 via a slider. A first drive assembly is mounted on the first frame 603, including a second drive motor 606 fixedly mounted on the top of the first frame 603. A drive pulley 607 is fixedly mounted on the output end of the second drive motor 606. A second toothed plate 608 is fixedly mounted parallel to the bottom of the first guide rail 602. Rotary shaft seats 609 are fixedly mounted at both ends of the bottom of the first frame 603, and a connecting shaft 610 is rotatably connected between the two rotary shaft seats 609. Driven gears 611 are fixedly mounted at both ends of the connecting shaft 610, and the driven gears 611 mesh with the second toothed plate 608. A driven pulley 612 is fixedly mounted on one end of the connecting shaft 610, and the driving pulley 607 and the driven pulley 612 are connected by a transmission belt. When the second drive motor 606 rotates, it drives the connecting shaft 610 to rotate via belt transmission, and then drives the first frame 603 to move along the first guide rail 602 via gear and rack transmission. The second guide rail 604 is horizontally fixedly mounted on the two sides of the top of the first frame 603, and the second guide rail 604 is perpendicular to the first guide rail 602. A third horizontal moving mechanism is slidably mounted on the second guide rail 604. The third horizontal moving mechanism includes a second mounting plate 605, which is slidably connected to the two second guide rails 604 via a slider. A toothed plate 613 is fixedly mounted parallel to the side of guide rail 2 604. A drive motor 614 is fixedly mounted on the top side of mounting plate 2 605. A drive gear 615 is fixedly mounted on the output end of drive motor 3 614, and drive gear 615 meshes with toothed plate 3 613. When drive motor 3 614 rotates, it drives mounting plate 2 605 to move along guide rail 2 604 through gear and rack transmission. A lifting mechanism 2 is fixedly mounted on mounting plate 2 605. The lifting mechanism 2 includes a guide frame 616 vertically fixed on mounting plate 2 605. A column 617 is vertically slidably connected to guide frame 616 via a slider. A toothed plate 618 is vertically fixedly mounted on one side of column 617. A rotating shaft seat 619 is also fixedly mounted on mounting plate 2 605. The rotating shaft seat 619 is rotatably connected to drive gear 3 620 via a rotating shaft, and drive gear 3 620 meshes with toothed plate 4 618. A drive motor 621 is also fixedly mounted on mounting plate 605, and the output end of drive motor 621 is fixedly connected to the rotating shaft. When drive motor 621 rotates, it drives column 617 to move up and down through gear and rack transmission. A horizontally set pneumatic internal chuck 622 is fixedly mounted on the bottom of column 617. The pneumatic internal chuck 622 has a self-locking function in case of power failure or air failure, which can prevent the workpiece from falling in case of accidental power failure or air failure.

[0056] In this embodiment, the safety guardrail assembly 8 completely encloses the demagnetizing mechanism assembly 3, the magnetizing robot assembly 4, and the two unloading conveying mechanisms 5. The safety guardrail assembly 8 includes an access safety door 801 and two lifting doors 802. The access safety door 801 is equipped with three interlocking locks; if any lock is opened, the equipment immediately stops and an alarm sounds. The two lifting doors 802 are respectively located above the discharge ends of the two unloading conveying mechanisms 5. When the pallet is full, the corresponding lifting door 802 automatically rises to facilitate manual pallet replacement, and automatically closes after replacement.

[0057] In this embodiment, the anechoic chamber assembly 9 completely encloses the feeding mechanism 1, the flaw detector assembly 2, the demagnetizing mechanism assembly 3, and the magnetizing robot assembly 4. The anechoic chamber assembly 9 is made of light-shielding and radiation-proof materials, and its side walls are respectively provided with an inlet for the feeding mechanism 1 and an outlet for the demagnetizing mechanism assembly 3. The anechoic chamber assembly 9 is equipped with a ventilation system, an emergency lighting system, and a smoke alarm system, which can effectively isolate strong magnetic field radiation and ultraviolet radiation damage.

[0058] The working principle and usage steps of the above technical solution are as follows:

[0059] First, perform pre-start preparations, ensuring there are no obstructions around the equipment, the ground is clean and dry, and the ambient temperature and humidity meet the equipment's operating requirements; confirm that the three-phase power supply connection is normal, the grounding resistance meets the standard, and all switches in the distribution cabinet are in the off position; confirm that the compressed air pressure meets the requirements and there are no leaks in the pipeline; confirm that the magnetic suspension concentration meets the standard, the fluorescent lamps are working properly, and the qualified and defective product trays are placed in place; confirm that all safety doors are closed, the emergency stop button is reset, and the alarm lights are working properly.

[0060] After completing the pre-start preparations, switch the machine model and set the parameters. Rotate the handwheels of the feeding mechanism 1 and the demagnetizing mechanism assembly 3 to adjust the distance between guide rod 102 and guide rod 302 to match the full length of the support roller to be tested. Adjust the air pressure of the telescopic mechanism 412 on the magnetizing manipulator assembly 4 to match the gripping force of the boom 411 with the weight of the support roller. Set the circumferential demagnetizing current and longitudinal demagnetizing magnetomotive force on the equipment touch screen. Place the standard crack test block corresponding to the machine model, run the calibration program, and ensure that the AI ​​recognition accuracy meets the requirements.

[0061] After parameter settings are completed, the equipment is started and enters automatic operation mode. The operator neatly places the support rollers to be inspected on the guide rod 102 of the feeding mechanism 1, ensuring they do not exceed the guide rod's range. The feeding mechanism 1 drives the support rollers to be conveyed at a constant speed towards the flaw detector assembly 2, automatically stopping at the end under the action of the limit baffle. The three gripping mechanisms of the magnetized manipulator assembly 4 simultaneously descend to grip the workpieces at the corresponding positions, then move horizontally one station distance, placing the workpiece to be inspected at the inspection station of the flaw detector assembly 2, the inspected workpiece at the feeding end of the demagnetizing mechanism assembly 3, and the demagnetized workpiece at the unloading waiting position. The flaw detector assembly 2 clamps the workpiece and rotates it 360°. The magnetic suspension spray system automatically sprays fluorescent magnetic powder, and a high-definition industrial camera acquires images of the workpiece surface from multiple angles and transmits them to the AI ​​recognition system. The AI ​​system automatically identifies the location, length, and depth of cracks through deep learning algorithms, and sends the inspection result signal to the control system after the inspection is completed. The inspected workpieces are transferred to the demagnetizing mechanism assembly 3 and slowly pass through the demagnetizing coil along the guide rod 302, where they are demagnetized under the influence of an alternating magnetic field. Based on the detection signal sent by the flaw detector assembly 2, the unloading robot assembly 6 drives the pneumatic internal gripper 622 to grasp the demagnetized support rollers, transferring qualified products to the qualified product unloading conveyor 5 and defective products to the defective product unloading conveyor 5. When a pallet on a certain unloading conveyor 5 is full, the corresponding lifting and closing door 802 automatically rises, and a yellow alarm light flashes to prompt manual pallet replacement. After replacement, pressing the "confirm" button automatically closes the lifting and closing door 802, and the equipment resumes operation. The equipment repeats the above steps to achieve continuous automated production.

[0062] The above are merely preferred embodiments of the present invention; however, the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and its improved concept, should be covered within the scope of protection of the present invention.

Claims

1. A fully automatic loading, unloading, inspection, and sorting device for support rollers, characterized in that, include: The feeding mechanism (1) is used to transport the support rollers to be tested; Flaw detector assembly (2), used for flaw detection of support rollers; The demagnetizing mechanism assembly (3) is used to demagnetize the support rollers after the test is completed; The magnetized manipulator assembly (4) is used to grasp the support rollers and transfer them between the feeding mechanism (1), the flaw detector assembly (2), and the demagnetizing mechanism assembly (3); Two unloading conveyor mechanisms (5) are used to convey qualified product pallets and defective product pallets, respectively; The unloading robot assembly (6) is used to grab the support rollers from the demagnetizing mechanism assembly (3) and transfer them to one of the unloading conveyor mechanisms (5); The feeding mechanism (1), the flaw detector assembly (2), and the demagnetizing mechanism assembly (3) are arranged in a straight line, and the conveying direction of the feeding mechanism (1) is perpendicular to the conveying direction of the unloading conveying mechanism (5).

2. The fully automatic loading, unloading, detection, and sorting equipment for support rollers according to claim 1, characterized in that, It also includes a safety guardrail assembly (8) for enclosing the demagnetizing mechanism assembly (3), the magnetizing manipulator assembly (4) and the two unloading conveying mechanisms (5). The safety guardrail assembly (8) includes an inlet and outlet safety door (801) and two lifting opening and closing doors (802). The two lifting opening and closing doors (802) are respectively located above the discharge end of the two unloading conveying mechanisms (5).

3. The fully automatic loading, unloading, detection, and sorting equipment for support rollers according to claim 1, characterized in that, It also includes a darkroom assembly (9), which encloses the feeding mechanism (1), the flaw detector assembly (2), the demagnetizing mechanism assembly (3), and the magnetizing manipulator assembly (4). The darkroom assembly (9) has a feed inlet for the feeding mechanism (1) to extend out and a discharge outlet for the demagnetizing mechanism assembly (3) to extend out.

4. The fully automatic loading, unloading, detection, and sorting equipment for support rollers according to claim 1, characterized in that, The feeding mechanism (1) includes a base (101), two guide rods (102) are arranged parallel to each other on the upper part of the base (101), guide rod supports (103) are respectively provided at both ends of the guide rods (102), and screws (104) are arranged at both ends of the base (101) perpendicular to the guide rods (102). The screws (104) are respectively threaded to the bottom of the guide rod supports (103) on the same side. The screws (104) have opposite thread directions on the left and right halves. The thread directions of the threaded holes on the guide rod supports (103) on the same guide rod (102) are the same. The ends of the two screws (104) on the same side are provided with sprockets (105). The two sprockets (105) are connected by a chain. One end of one of the screws (104) is provided with a handwheel.

5. The fully automatic loading, unloading, detection, and sorting equipment for support rollers according to claim 4, characterized in that, The demagnetizing mechanism assembly (3) includes a base two (301), with two guide rods two (302) arranged parallel to each other on the upper part of the base two (301). Guide rod supports (303) are respectively provided at both ends of the guide rods two (302). Screws two (304) are provided at both ends of the base two (301) perpendicular to the guide rods two (302). The screws two (304) are threaded to the bottom of the guide rod supports (303) on the same side. The left half of the screws two (304) and The right half of the thread has the opposite direction of rotation. The threaded holes on the guide rod support (303) on the same guide rod (302) have the same direction of rotation. Both ends of the two screw rods (304) on the same side are provided with sprockets (305). The two sprockets (305) are connected by a chain. One end of one of the screw rods (304) is provided with a handwheel. The two guide rods (302) near the flaw detector assembly (2) are provided with a demagnetizing mechanism (306).

6. The fully automatic loading, unloading, detection, and sorting equipment for support rollers according to claim 1, characterized in that, The magnetized manipulator assembly (4) includes a support frame (401), a support beam (402) is provided on the top of the support frame (401), a horizontal moving mechanism (402) is provided on the support beam (402), a lifting mechanism (403) is provided on the horizontal moving mechanism (402), a mounting bracket (403) is provided at the lower end of the lifting mechanism (403), and three gripping mechanisms (403) are provided on the mounting bracket (403) along the moving direction of the horizontal moving mechanism (403). The interval between the three gripping mechanisms (403) is the same as the distance between the end of the feeding mechanism (1), the detection station of the flaw detector assembly (2), and the feeding end of the demagnetizing mechanism assembly (3).

7. The fully automatic loading, unloading, detection, and sorting equipment for support rollers according to claim 6, characterized in that, The horizontal moving mechanism includes a mounting plate (404), which is slidably mounted on a support beam (402). A telescopic mechanism (405) is provided on the mounting plate (404). The extended end of the telescopic mechanism (405) is connected to the support frame (401). The telescopic direction of the telescopic mechanism (405) is the same as the arrangement direction of the feeding mechanism (1), the flaw detector assembly (2), and the demagnetizing mechanism assembly (3). The lifting mechanism includes a vertical rail (406), a connecting frame (407) slidably mounted on the vertical rail (406), a toothed plate (408) on one side of the connecting frame (407), a drive motor (409) mounted on the mounting plate (404), and a drive gear (410) at the output end of the drive motor (409), which meshes with the toothed plate (408). The gripping mechanism includes two oppositely arranged booms (411). The booms (411) are slidably arranged at the bottom of the mounting bracket (403). The booms (411) have an L-shaped structure. The top of the mounting bracket (403) is provided with telescopic mechanisms (412) corresponding to the booms (411). The extended ends of the telescopic mechanisms (412) are oppositely arranged and connected to the corresponding booms (411).

8. The fully automatic loading, unloading, detection, and sorting equipment for support rollers according to claim 1, characterized in that, The unloading robot assembly (6) includes a second bracket (601). The top of the second bracket (601) is provided with a guide rail (602) perpendicular to the conveying direction of the unloading conveying mechanism (5). A second horizontal moving mechanism is provided on the guide rail (602). The second horizontal moving mechanism includes a first frame (603). The first frame (603) slides on the first guide rail (602). A first drive component is also provided on the first frame (603). Two guide rails (604) are horizontally provided on the top two sides of the first frame (603). A third horizontal moving mechanism is provided on the second guide rail (604). The second guide rail (604) is perpendicular to the first guide rail (602). The third horizontal moving mechanism includes a second mounting plate (605). The second mounting plate (605) slides on the two second guide rails (604). A second lifting mechanism is provided on the second mounting plate (605). A second gripping mechanism is provided at the bottom of the second lifting mechanism.

9. A fully automatic loading, unloading, detection, and sorting device for support rollers according to claim 8, characterized in that, The drive assembly includes a second drive motor (606), which is located on the top of the frame (603). The output end of the second drive motor (606) is equipped with a drive pulley (607). A toothed plate (608) is provided parallel to the bottom of the guide rail (602). Rotary shaft seats (609) are located at both ends of the bottom of the frame (603). A connecting shaft (610) is located between the two rotary shaft seats (609). Driven gears (611) are located at both ends of the connecting shaft (610), meshing with the toothed plate (608). A driven pulley (612) is also provided at one end of the connecting shaft (610). The drive pulley (607) and the driven pulley (612) are connected by a belt drive. A toothed plate three (613) is provided parallel to the side of the guide rail two (604). A drive motor three (614) is provided on the top side of the mounting plate two (605). A drive gear two (615) is provided at the output end of the drive motor three (614). The drive gear two (615) meshes with the toothed plate three (613). A guide frame (616) is vertically mounted on the mounting plate two (605). A column (617) is vertically slidably mounted on the guide frame (616). A toothed plate four (618) is vertically mounted on the column (617). A rotating shaft seat two (619) is also mounted on the mounting plate two (605). A drive gear three (620) is rotatably mounted on the rotating shaft of the rotating shaft. The drive gear three (620) meshes with the toothed plate four (618). A drive motor four (621) is also mounted on the mounting plate two (605). The output end of the drive motor four (621) is connected to the rotating shaft. The second gripping mechanism is a horizontally arranged pneumatic internal gripper (622).

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