Intelligent unhooking fluorescence magnetic powder flaw detection integrated testing device and method

Abstract

The application discloses an intelligent unhooking fluorescent magnetic powder flaw detection integrated inspection device and method, which comprises: a feeding platform mechanism for conveying unhookings to be inspected to subsequent processing stations; a double-station ultrasonic cleaning mechanism for cleaning the unhookings to be inspected before and after flaw detection; a fluorescent magnetic powder flaw detection mechanism for displaying the defect position and form of the unhookings to be inspected; a camera recognition mechanism for collecting images of the unhookings to be inspected; an air-drying and spraying mechanism for air-drying and spraying the unhookings after inspection; a storage box for storing the unhookings after inspection; a six-axis mechanical arm carrying mechanism for carrying the unhookings; and a main controller for linkage control between the mechanisms. The application has the advantages of high automation, high detection precision, stable demagnetization effect, traceable data, strong adaptability, safety and reliability.

Description

Technical Field

[0001] This invention belongs to the field of non-destructive testing technology for shackles, specifically relating to an integrated intelligent shackle fluorescent magnetic particle flaw detection device and method. Background Technology

[0002] As a critical load-bearing component in engineering machinery, shipbuilding, and lifting and transportation industries, shackles are highly susceptible to defects such as surface and near-surface cracks, which directly impact operational safety. Traditional shackle inspection often relies on manual operation of magnetic particle testing equipment, a method with the following drawbacks: 1. Incomplete manual cleaning can leave oil and rust residue in threads and gaps, affecting the accuracy of testing. 2. The magnetization method is singular, making it impossible to achieve targeted detection of the buckle and pin, resulting in a high risk of missed detection; 3. Defect identification relies on manual visual judgment, which is highly subjective, inefficient, and makes it difficult to trace the detection data; 4. The demagnetizing effect is unstable, and the residual magnetic field can easily cause impurities to be attracted during subsequent use of the shackle; 5. The various testing processes are scattered, manual handling is time-consuming, and the overall testing cycle is long, which cannot meet the needs of large-scale production.

[0003] Existing magnetic particle inspection equipment is mostly designed for single functions and lacks integrated intelligent solutions, making it difficult to adapt to container operation scenarios and resulting in insufficient versatility and automation. Summary of the Invention

[0004] This invention is proposed to solve the technical problems existing in the traditional shackle inspection, such as incomplete cleaning, poor magnetization targeting, strong subjectivity in defect identification, poor demagnetization effect, low efficiency due to dispersed processes, and insufficient adaptability. Its purpose is to provide an intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device and method.

[0005] This invention is achieved through the following technical solution: A smart shackle fluorescent magnetic particle flaw detection integrated inspection device includes: The feeding platform mechanism is used to transport the shackles to be inspected to the subsequent processing station. A dual-station ultrasonic cleaning system is used for cleaning shackles to be inspected before and after flaw detection. Fluorescent magnetic particle inspection system, used to display the location and shape of defects in shackles to be inspected; A camera recognition system is used to capture images of shackles to be inspected; The rinsing, air-drying, and spraying mechanism is used for air-drying and spraying treatment of the unfastened parts after inspection. Storage bin, used to store shackles after inspection; A six-axis robotic arm handling mechanism used for handling shackles; The main controller is used for the coordinated control between various mechanisms.

[0006] In the above technical solution, the feeding platform mechanism includes a feeding platform, a drive mechanism, and a shackle tray; the drive mechanism includes a geared motor, a sprocket assembly, and a chain; the geared motor is mounted on the feeding platform mechanism via a motor mounting bracket; the chain is wound around the sprocket assembly and meshes with it; the sprocket assembly includes a drive sprocket, a tensioning wheel assembly, and a transition wheel arranged sequentially along the transmission direction; the drive sprocket is mounted on the drive shaft of the geared motor; the tensioning wheel assembly is mounted on the feeding platform mechanism via a tensioning wheel mounting bracket; the transition wheel is mounted on the feeding platform mechanism via a transition wheel mounting bracket; the shackle tray includes a tray, two support beams mounted on the tray, a drive wheel mounted at the bottom of the tray, and a chain connecting ear mounted at the bottom of the tray; the drive wheel meshes with the chain, and the chain connecting ear is connected to the chain; one support beam is used to place the shackle body part after disassembly; the other support beam is used to place the pin part after disassembly.

[0007] In the above technical solution, the dual-station ultrasonic cleaning mechanism includes a pre-detection ultrasonic cleaning mechanism disposed between the feeding platform mechanism and the fluorescent magnetic particle flaw detection mechanism, and a post-detection ultrasonic cleaning mechanism disposed between the camera recognition mechanism and the air drying module of the air drying spraying mechanism. The ultrasonic cleaning mechanism before and after flaw detection has the same structure, both including an outer shell and a cleaning tank, a filter water tank and a self-priming pump installed inside the outer shell; the self-priming pump is connected to the cleaning tank through a water supply pipe, and a pre-filter is installed on the water supply pipe; the inlet of the self-priming pump is connected to the filter water tank through a pipeline; multiple ultrasonic transducers are installed at the bottom of the cleaning tank; an electric heating tube and a temperature sensor are installed inside the filter water tank.

[0008] In the above technical solution, the fluorescent magnetic particle flaw detection mechanism includes a flaw detection frame, a magnetization unit, a magnetic suspension spraying and recovery unit, and a demagnetization unit installed on the flaw detection frame.

[0009] In the above technical solution, the magnetization unit includes a buckle magnetization unit and a pin magnetization unit; the magnetization unit uses independently set circumferential magnetization transformer and longitudinal magnetization transformer as magnetization power supply; The fastener magnetization unit mechanism includes a yoke moving mechanism, a rod-through yoke closing mechanism, a rod-through yoke repositioning mechanism, a fastener placement platform, and a lower yoke. The rod-through yoke repositioning mechanism is mounted on the side of the rod-through yoke closing mechanism via a rotating shaft. The other side of the rod-through yoke closing mechanism is slidably connected to a guide rail mounted on the side of the yoke moving mechanism via a slider. The closing and opening of the rod-through yoke is achieved by a closing cylinder. The yoke moving mechanism is slidably connected to a guide rail mounted on the flaw detector frame via a lower slider. The movement of the moving yoke is achieved by a moving cylinder. The lower yoke and fastener placement platform are also included. The pin-shaft magnetization unit mechanism includes a left-moving magnetic yoke mechanism, a right-moving magnetic yoke mechanism, a left magnetic yoke rotation mechanism, a U-shaped fixed magnetic yoke mechanism, and a pin-shaft rotation mechanism. The left-moving magnetic yoke mechanism and the right-moving magnetic yoke mechanism are movably connected to the U-shaped fixed magnetic yoke mechanism via left and right guide wheel seats mounted on the front and rear sides of the U-shaped fixed magnetic yoke mechanism. The left and right moving magnetic yokes are closed using the left magnetic yoke rotation mechanism, synchronous chain, sprocket, and magnetization clamping cylinder. The U-shaped fixed magnetic yoke mechanism is mounted on the frame. The pin-shaft rotation mechanism is driven by a geared motor and is mounted on the flaw detector frame. The magnetic suspension spraying and recovery unit includes a magnetic suspension storage tank, a pump motor, pipelines, valves, a spraying system with spray heads, and a magnetic suspension collection tank. The spray heads of the spraying system are installed on the flaw detector frame and are used to spray the magnetic suspension evenly onto the surfaces of the buckle and cross pin. The magnetic suspension collection tank is installed on the flaw detector frame and is used to collect the sprayed magnetic suspension and return it to the magnetic suspension tank. The magnetic suspension collection tank is located below the flaw detection station.

[0010] In the above technical solution, the demagnetizing unit is used to eliminate the residual magnetism left by the shackle after magnetization; the demagnetizing unit consists of a conveying device and a demagnetizing coil; the demagnetizing coil is made of insulating epoxy board as skeleton, double glass wire wrapped with wire, 1000±50 turns, and insulation resistance ≥10MΩ.

[0011] In the above technical solution, the camera recognition mechanism includes a buckle camera mechanism and a pin camera mechanism; The buckle camera mechanism includes a rotating arm rotary cylinder fixed to the crossbeam of the truss robotic arm, a rotating arm connected to the output shaft of the rotating arm rotary cylinder, a camera rotary cylinder connected to the other end of the rotating arm, and a buckle camera unit connected to the output shaft of the camera rotary cylinder; the buckle camera unit includes a buckle camera frame connected to the output shaft of the camera rotary cylinder, and a high-definition camera and an ultraviolet lamp mounted on the buckle camera frame; The pin-type camera mechanism includes a pin-type camera frame and a high-definition camera and an ultraviolet lamp mounted on the pin-type camera frame; the pin-type camera frame is located between the flaw detection host and the cleaning and drying mechanism.

[0012] In the above technical solution, the rinsing, air-drying and spraying mechanism includes a rinsing and air-drying mechanism, a spraying mechanism and a hot air drying mechanism arranged in sequence according to the process. The rinsing and drying mechanism includes a water rinsing and drying unit, a U-shaped rinsing and drying frame, a lower rinsing water tank, multiple fixed rinsing nozzles connected to the rinsing water tank via pipelines, and a pulse generator installed on the outer side wall of the rinsing and drying frame. The fixed rinsing nozzles are fixed to the bottom beam of the rinsing and drying frame by brackets, and the nozzles of the fixed rinsing nozzles are aligned with the shackles. The pulsed compressed air generated by the pulse solenoid valve on the pulse generator is connected to the nozzle of the water rinsing and drying unit through a hose. The nozzle is aligned with the shackles, and the water rinsing and drying unit moves while blowing air to dry the water on the shackles. The water rinsing and drying unit includes a drive mechanism, a moving guide rail, a nozzle, and a nozzle bracket. The nozzle is installed on the nozzle bracket, and the nozzle bracket is connected to the output shaft of the drive mechanism. The drive mechanism drives the nozzle bracket to move on the moving guide rail. The hot air drying mechanism includes a hot air dryer frame, an electric heating hot air blower, and a liquid receiving tank connected to the top beam of the hot air dryer frame; the electric heating hot air blower is connected to the liquid receiving tank through the hot air blower outlet pipe; a support net is set in the liquid receiving tank, and the shackle is placed on the support net. The spraying mechanism includes a spraying frame, an inner spraying chamber, and a spraying cylinder fixed to the top of the spraying frame via a spraying cylinder fixing plate. The free end of the piston rod of the spraying cylinder is connected to the spraying cylinder connecting plate, and the lower part of the spraying cylinder connecting plate is connected to the spraying nozzle fixing frame. The lower part of the spraying nozzle fixing frame is slidably connected to the spraying guide rail fixed on the spraying frame via a spraying slider. The spraying nozzle fixing frame is U-shaped, with two spraying nozzles fixed to the two free ends of the spraying nozzle fixing frame, and the two spraying nozzles are located on the upper and lower sides of the shackle. The inner spraying chamber is located on the upper part of the spraying frame, and all other components of the spraying mechanism, except for the spraying frame, are located above the inner spraying chamber.

[0013] In the above technical solution, the six-axis robotic arm handling mechanism includes at least two six-axis robotic arms and a shackle clamp disposed at the free end of the six-axis robotic arm; the shackle clamp includes a shackle loading clamp and a shackle unloading clamp; The shackle loading fixture includes an upper clamp upper support plate, an upper clamp lower support plate, an upper clamp slide rail, an upper clamp side connecting plate, an upper clamp rear connecting plate, an upper clamp clamping cylinder, an upper clamp left clamping claw, an upper clamp right clamping claw, an upper clamping claw sliding seat, an upper clamp synchronous gear, and an upper clamp synchronous rack. The upper clamp slide rail is located on the top of the lower upper clamp support plate; the upper clamp synchronous gear is mounted on the middle of the lower upper clamp support plate via the upper clamp gear seat; the upper and lower upper clamp support plates are arranged parallel to each other vertically, and the upper clamp side connecting plate and the upper clamp rear connecting plate are arranged parallel to each other, both positioned between the upper and lower upper clamp support plates, with both ends connected to the upper and lower upper clamp support plates respectively; the upper clamp rear connecting plate is connected to the six-axis robotic arm; the upper clamp clamping cylinder is located via the upper clamp cylinder seat. Mounted on the upper support plate of the upper clamp, the free end of the piston of the upper clamping cylinder is connected to the upper clamping jaw sliding seat, and the bottom of the upper clamping jaw sliding seat is connected to the upper clamping right clamping jaw; the upper clamping left and right clamping jaws are both slidably connected to the upper clamping slide rail through the upper clamping slider; the rear ends of the upper clamping left and right clamping jaws are provided with upper clamping synchronous racks, and the upper clamping synchronous racks at the rear ends of the upper clamping left and right clamping jaws are distributed on both sides of the upper clamping synchronous gear, and both are meshed with the upper clamping synchronous gear; The shackle unloading fixture includes a lower clamping plate, an upper clamping plate, a side connecting plate, a rear connecting plate, a clamping cylinder, a left clamping jaw, a right clamping jaw, a jaw sliding seat, a synchronizing gear, and a synchronizing rack. The lower clamping slide rail is located on the top of the lower clamping plate. The synchronizing gear is mounted on the middle of the lower clamping plate via a gear seat. The upper and lower clamping plates are arranged parallel vertically, and the side and rear connecting plates are also parallel, both positioned between the upper and lower clamping plates, with both ends connected to the upper clamping plate. The lower support plate and the lower clamp are connected; the rear connecting plate of the lower clamp is connected to the six-axis robotic arm; the clamping cylinder of the lower clamp is mounted on the upper support plate of the lower clamp through the lower clamp cylinder seat, the free end of the piston of the lower clamping cylinder is connected to the sliding seat of the lower clamp claw, and the bottom of the sliding seat of the lower clamp claw is connected to the right clamping claw of the lower clamp; the left and right clamping claws of the lower clamp are slidably connected to the lower clamp slide rail through the lower clamp slider; the rear ends of the left and right clamping claws of the lower clamp are provided with lower clamp synchronous racks, and the lower clamp synchronous racks at the rear ends of the left and right clamping claws of the lower clamp are distributed on both sides of the lower clamp synchronous gear, and both are meshed with the lower clamp synchronous gear.

[0014] An inspection method based on the aforementioned intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device includes the following steps: S1. Place the shackle on the feeding platform mechanism, and the feeding platform mechanism will transport the shackle to the ultrasonic cleaning mechanism before flaw detection of the dual-station ultrasonic cleaning mechanism. S2. The ultrasonic cleaning mechanism cleans the shackles before flaw detection. S3, the six-axis robotic arm transport mechanism transports the cleaned shackles from the ultrasonic cleaning mechanism before flaw detection to the fluorescent magnetic particle flaw detection mechanism. S4. Select a suitable magnetization method according to the shape and size of the shackle. Apply a magnetic field to the shackle through the shackle body magnetization unit and the pin magnetization unit. At the same time, the magnetic suspension spraying and recovery system sprays the magnetic suspension evenly on the surface of the shackle. S5. The ultraviolet lamp of the camera recognition mechanism provides ultraviolet light to excite the fluorescent magnetic powder to emit light. The high-definition camera captures the magnetic trace image on the surface of the shackle. The industrial control computer uses the point-by-point scanning color gradation method and AI semantic segmentation algorithm to process the image, automatically identify crack defects, extract parameters such as the number, coordinate position and length of cracks, and identify the identification information of the shackle tonnage and number, and generate an inspection report. S6. The demagnetizing mechanism of the fluorescent magnetic particle inspection system adopts a remote combined automatic attenuation demagnetizing technology to demagnetize the shackles. S7, the six-axis robotic arm transport mechanism transports the demagnetized shackle to the ultrasonic cleaning mechanism after flaw detection in the dual-station ultrasonic cleaning mechanism. S8. After flaw detection, the shackle is cleaned again by the ultrasonic cleaning mechanism. S9. The air-drying module of the air-drying spraying mechanism performs air-drying treatment on the shackles; S10, The spraying module of the air-drying spraying mechanism sprays a protective coating onto the surface of the shackle; S11, the six-axis robotic arm handling mechanism transports the inspected and processed shackles to the storage box, completing the entire inspection process.

[0015] The beneficial effects of this invention are: This invention provides an integrated, intelligent, efficient, and reliable intelligent shackle fluorescent magnetic particle flaw detection device and method, which has the following advantages: 1. High degree of automation: It can realize the fully automated operation of "cleaning-magnetic flaw detection-defect identification-demagnetization-drying-spraying-storage", eliminating the need for manual handling and visual judgment, and greatly reducing labor costs; 2. High detection accuracy: Dual-station cleaning ensures workpiece cleanliness, a targeted composite magnetization system is adapted for buckle and pin detection, and AI intelligent recognition algorithm avoids human subjective error. The defect recognition accuracy can reach 100%, completely eliminating missed detections. 3. Stable demagnetization effect: The attenuation demagnetization technology ensures that the residual magnetism is ≤3Gs, which meets the requirements for subsequent use; the magnetic suspension recycling design is energy-saving and environmentally friendly. 4. Data traceability: It can automatically record testing parameters, defect information and product identification, and intelligently generate inspection reports, which facilitates quality control and traceability; 5. Strong adaptability: The overall size is adapted to operation inside the container, supports 3 / 4 to 1-1 / 4 (1-3 / 8) specification shackles and pin inspection, and the modular design facilitates maintenance; 6. Safe and reliable: It has multiple safety protection mechanisms and process linkage control to avoid operational risks and process errors. The equipment noise is ≤80dB, which meets the requirements of industrial operation environment. Attached Figure Description

[0016] Figure 1 This is the front view of the present invention; Figure 2 This is the left view of the present invention; Figure 3 This is a top view of the present invention; Figure 4 This is a front view of the feeding platform mechanism in this invention; Figure 5 This is a left view of the feeding platform mechanism in this invention; Figure 6 This is a top view of the feeding platform mechanism in this invention; Figure 7 This is a front view of the ultrasonic cleaning mechanism before or after flaw detection in this invention. Figure 8 This is a left view of the ultrasonic cleaning mechanism before or after flaw detection in this invention. Figure 9 This is a top view of the ultrasonic cleaning mechanism before or after flaw detection in this invention. Figure 10 This is a front view of the fluorescent magnetic particle flaw detection mechanism in this invention; Figure 11 This is a left view of the fluorescent magnetic particle flaw detection mechanism in this invention; Figure 12 This is a top view of the fluorescent magnetic particle flaw detection mechanism in this invention; Figure 13 This is a front view of the buckle body flaw detection mechanism in this invention; Figure 14 This is a top view of the buckle body flaw detection mechanism in this invention; Figure 15 This is a left view of the buckle body flaw detection mechanism in this invention; Figure 16 This is a front view of the transverse pin flaw detection mechanism in this invention; Figure 17 This is a top view of the transverse pin flaw detection mechanism in this invention; Figure 18 This is a front view of the camera recognition mechanism in this invention; Figure 19 This is a left view of the camera recognition mechanism in this invention; Figure 20 This is a top view of the camera recognition mechanism in this invention; Figure 21 This is a front view of the rinsing and drying mechanism in this invention; Figure 22 This is a left view of the rinsing and drying mechanism in this invention; Figure 23 This is a top view of the rinsing and drying mechanism in this invention; Figure 24 This is a front view of the hot air drying mechanism in this invention; Figure 25 This is a left view of the hot air drying mechanism in this invention; Figure 26 This is a top view of the hot air drying mechanism in this invention; Figure 27 This is a front view of the spraying mechanism in this invention; Figure 28 This is a left view of the spraying mechanism in this invention; Figure 29 This is a top view of the spraying mechanism in this invention; Figure 30 This is a front view of the shackle loading clamp in this invention; Figure 31 This is a left view of the shackle loading clamp in this invention; Figure 32 This is a top view of the shackle loading clamp in this invention; Figure 33 This is a front view of the shackle unloading fixture in this invention; Figure 34 This is a left view of the shackle unloading fixture in this invention; Figure 35 This is a top view of the shackle unloading fixture in this invention.

[0017] in: 1. Feeding platform mechanism; 11. Feeding platform; 12. Shackle tray; 13. Gear motor; 14. Chain; 15. Drive sprocket; 16. Tensioner wheel fixing bracket; 17. Transition wheel; 18. Transition wheel fixing bracket; 19. Motor fixing bracket; 110. Chain connecting lug; 2. Ultrasonic cleaning mechanism before flaw detection; 21. Housing; 22. Cleaning tank; 23. Ultrasonic transducer; 24. Pre-filter; 25. Water supply pipe; 26. Filter water tank; 27. Temperature sensor; 28. Electric heating element; 29. ​​Self-priming pump; 3. Fluorescent magnetic particle inspection mechanism; 31. Inspection frame; 32. Magnetic suspension liquid collection tank; 33. Button magnetization unit; 34. Magnetic suspension liquid spraying and recovery unit; 35. Pin magnetization unit; 36. Circumferential magnetization transformer; 37. Longitudinal magnetization transformer; 38. Magnetic yoke moving mechanism; 39. Rod-through magnetic yoke closing mechanism; 310. Rod-through magnetic yoke repositioning mechanism; 311. Button placement platform; 312. Lower magnetic yoke; 313. Left magnetic yoke rotation mechanism; 314. Left moving magnetic yoke mechanism; 315. Left guide wheel seat plate; 316. Pin rotation mechanism; 317. U-shaped fixed magnetic yoke mechanism; 318. Right guide wheel seat plate; 319. Clamping cylinder connector fixing plate; 320. Magnetized clamping cylinder; 321. Right moving magnetic yoke mechanism; 4. Camera recognition mechanism; 41. Rotating arm rotary cylinder; 42. Rotating arm; 43. Camera rotary cylinder; 44. Snap-on camera unit; 45. Pin-type camera mechanism; 5. Ultrasonic cleaning mechanism after flaw detection; 6. Washing and drying mechanism; 61. Pulse generator; 62. Washing and drying unit; 63. Washing and drying frame; 64. Washing water tank; 65. Fixed water spray nozzle; 7. Hot air drying mechanism; 71. Hot air dryer frame; 72. Liquid receiving tank; 73. Hot air blower outlet pipe; 74. Electric heating hot air blower; 8. Spraying mechanism; 81. Spraying machine frame; 82. Spraying inner box; 83. Spraying nozzle; 84. Spraying nozzle fixing bracket; 85. Spraying guide rail fixing plate; 86. Spraying cylinder connecting plate; 87. Spraying cylinder; 88. Spraying cylinder fixing plate; 89. Spraying guide rail; 810. Spraying slider; 9. Storage bins; 10. Six-axis robotic arm; 11. Shackle loading fixture; 111. Upper fixture upper support plate; 112. Upper fixture lower support plate; 113. Upper fixture slide rail; 114. Upper fixture cylinder seat; 115. Upper fixture clamping cylinder; 116. Upper fixture slider; 117. Upper fixture left clamping jaw; 118. Upper fixture right clamping jaw; 119. Upper fixture jaw sliding seat; 1110. Upper fixture side connecting plate; 1111. Upper fixture middle connecting plate; 1112. Upper fixture synchronous rack; 1113. Upper fixture gear seat; 1114. Upper fixture synchronous gear; 1115. Upper fixture rear connecting plate; 1116. Upper fixture jaw teeth; 12. Shackle unloading fixture; 121. Lower fixture lower support plate; 122. Lower fixture upper support plate; 123. Lower fixture slide rail; 124. Lower fixture cylinder seat; 125. Lower fixture clamping cylinder; 126. Lower fixture slider; 127. Lower fixture left clamping jaw; 128. Lower fixture right clamping jaw; 129. Lower fixture jaw sliding seat; 1210. Lower fixture side connecting plate; 1211. Lower fixture jaw teeth; 1212. Lower fixture intermediate sleeve; 1213. Lower fixture synchronous rack; 1214. Lower fixture gear seat; 1215. Lower fixture synchronous gear; 1216. Lower fixture rear connecting plate.

[0018] For those skilled in the art, other related figures can be obtained from the above figures without any creative effort. Detailed Implementation

[0019] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0020] Example 1

[0021] like Figures 1-3 As shown, an intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device includes a feeding platform mechanism 1, a dual-station ultrasonic cleaning mechanism, a fluorescent magnetic particle flaw detection mechanism 3, a camera recognition mechanism 4, a rinsing, air drying and spraying mechanism, a storage box 8, a six-axis robotic arm handling mechanism and a main controller. like Figures 4-6 As shown, the feeding platform mechanism 1 is used to transport the shackles to be inspected in an orderly and stable manner to the working range of the six-axis robotic arm handling mechanism, so that the six-axis robotic arm handling mechanism can grab the shackles and put them into the dual-station ultrasonic cleaning mechanism; the feeding platform mechanism 1 can adjust the conveying speed and rhythm according to the actual production needs, so as to achieve seamless docking with the subsequent stations and improve the efficiency of the entire inspection process. The feeding platform mechanism 1 includes a feeding platform 11, a drive mechanism, and a shackle tray 12; the drive mechanism includes a geared motor 13, a sprocket assembly, and a chain 14; the geared motor 13 is mounted on the feeding platform mechanism 1 via a motor mounting bracket 19; the chain 14 is wound around the sprocket assembly and meshes with it to achieve transmission between the sprocket assembly and the chain 14; the sprocket assembly includes a drive sprocket 15, a tensioning wheel assembly, and a transition wheel 17 arranged sequentially along the transmission direction; the drive sprocket 15 is mounted on the drive shaft of the geared motor 13; the tensioning wheel assembly is mounted on the feeding platform mechanism 1 via a tensioning wheel mounting bracket 16; the transition wheel 17 is mounted on the feeding platform mechanism 1 via a transition wheel mounting bracket 18; the shackle tray 12 includes a tray, two support beams mounted on the tray, a drive wheel mounted at the bottom of the tray, and a chain connecting lug 110 mounted at the bottom of the tray; the drive wheel and the chain 14... 4. Engagement: The chain connecting lug 110 is connected to the chain 14, and the two work together to move the shackle tray 12 under the drive of the chain 14. The shape of the support beam is adapted to the shape of the shackle. One beam is a shackle body support beam, which is used to place the shackle body part after disassembly. The shackle body part is fitted onto the shackle body support beam. The other beam is a pin shaft support beam, which is used to place the pin shaft part after disassembly. A pin shaft groove is formed at the top of the pin shaft support beam, and the pin shaft part is embedded in the pin shaft groove. The shackle tray 12 provides stable support for the various parts of the shackle after disassembly, which facilitates stable transportation of the shackle and makes it easy for the six-axis robotic arm handling mechanism to grasp it. The feeding platform 11 and the drive mechanism of the feeding platform mechanism 1 are conventional designs, as long as they can realize the transmission function, and are not limited to the methods disclosed in this invention. The shackle tray 12 of the feeding platform mechanism 1 is an innovative design of this invention specifically for shackles.

[0022] like Figures 7-9 As shown, the dual-station ultrasonic cleaning mechanism includes a pre-detection ultrasonic cleaning mechanism 2 located between the feeding platform mechanism 1 and the fluorescent magnetic particle flaw detection mechanism 3, and a post-detection ultrasonic cleaning mechanism 5 located between the camera recognition mechanism 4 and the air drying module 6 of the air drying spraying mechanism. The ultrasonic cleaning mechanism 2 before flaw detection and the ultrasonic cleaning mechanism 5 after flaw detection have the same structure, both including a housing 21 and a cleaning tank 22, a filter water tank 26, and a self-priming pump 29 disposed within the housing; the self-priming pump 29 is connected to the cleaning tank 22 via a water supply pipe 25, and a pre-filter 24 is installed on the water supply pipe 25; the inlet of the self-priming pump 29 is connected to the filter water tank 26 via a pipeline; multiple ultrasonic transducers 23 are installed at the bottom of the cleaning tank 22; an electric heating tube 28 and a temperature sensor 27 are installed inside the filter water tank 26; the power of the ultrasonic transducers 23 is... Adjustable within the range of 0~1500W; the cleaning tank 22 is made of corrosion-resistant material and has an inclined drain outlet at the bottom for easy discharge of impurities; the cleaning time of the ultrasonic cleaning mechanism 2 before flaw detection and the ultrasonic cleaning mechanism 5 after flaw detection can be set within the range of 10s~60s to adapt to workpieces with different levels of dirt; the ultrasonic cleaning mechanism 2 before flaw detection focuses on removing oil and rust to prepare for magnetized flaw detection; the ultrasonic cleaning mechanism 5 after flaw detection focuses on removing residual magnetic suspension to avoid affecting the subsequent air drying and spraying effect. After cleaning, the surface of the workpiece is undamaged and the residue rate is ≤0.5%; While ensuring detection accuracy, this application employs a dual-station ultrasonic cleaning mechanism with a dual-station design, corresponding to pre-detection pretreatment and post-detection cleaning respectively. Its core technology is the high-frequency ultrasonic cavitation effect: ultrasonic waves propagate in the cleaning fluid, forming alternating high-pressure and low-pressure zones. Microbubbles are generated in the low-pressure zone and rapidly burst, releasing a huge impact force to powerfully peel off oil, rust, and impurities from shackle threads and gaps, achieving deep cleaning without disassembly. The ultrasonic generators and cleaning tanks that make up the pre-detection ultrasonic cleaning mechanism 2 and the post-detection ultrasonic cleaning mechanism 5 are all conventional commercially available equipment.

[0023] like Figures 10-12 As shown, the fluorescent magnetic particle flaw detection mechanism 3 includes a flaw detection frame 31, a magnetization unit, a magnetic suspension spraying and recovery unit 34, and a demagnetization unit installed on the flaw detection frame 31. The magnetization unit is designed with zoned detection to address the structural differences between the buckle body and the pin shaft of the shackle. It includes a buckle body magnetization unit 33 and a pin shaft magnetization unit 35. The magnetization unit uses two independent magnetization power supplies, one circumferential and one longitudinal. The core components of the magnetization power supply are magnetization transformers, namely a circumferential magnetization transformer 36 and a longitudinal magnetization transformer 37. The cores of the two magnetization transformers are made of high-permeability silicon steel sheets to improve magnetic permeability. The primary coil is wound with double glass fiber coils, and the secondary coil is made of electrolytic copper busbars, which have excellent conductivity. The coil frame is made of insulating epoxy board to ensure safety and reliability under high voltage. The magnetization unit supports three magnetization modes, including: circumferential AC magnetization (suitable for detecting axial cracks), longitudinal AC magnetization (suitable for detecting transverse cracks), and composite magnetization (circumferential + longitudinal, suitable for detecting complex cracks). The magnetic yoke transposition and power supply switching are controlled by PLC to achieve targeted magnetization of the buckle body and the pin shaft.

[0024] like Figures 13-15 As shown, the snap body magnetization unit 33 and the pin magnetization unit 35 are respectively used to apply a suitable magnetic field to the snap body part and the pin part of the shackle, so that a leakage magnetic field is generated at the defect, attracting magnetic powder to form a magnetic trace, showing the location and shape of the defect. The button magnetization unit mechanism 33 includes a yoke moving mechanism 38, a rod-through yoke closing mechanism 39, a rod-through yoke repositioning mechanism 310, a button placement platform 311, and a lower yoke 312. The rod-through yoke repositioning mechanism 310 is mounted on the side of the rod-through yoke closing mechanism 39 via a rotating shaft. The other side of the rod-through yoke closing mechanism 39 is slidably connected to a guide rail mounted on the side of the yoke moving mechanism 38 via a slider. The closing and opening of the rod-through yoke is achieved by a closing cylinder. The yoke moving mechanism 38 is slidably connected to a guide rail mounted on the flaw detector frame 31 via a lower slider. The movement of the moving yoke is achieved by a moving cylinder. The lower yoke 312 and the button placement platform 311 are fixedly mounted on the flaw detector frame 31. like Figures 16-17 As shown, the pin-shaft magnetization unit mechanism 35 includes a left-moving magnetic yoke mechanism 314, a cylinder piston rod connecting head fixing plate 319, a magnetization clamping cylinder 320, a right-moving magnetic yoke mechanism 321, a left magnetic yoke rotation mechanism 313, a U-shaped fixed magnetic yoke mechanism 317, and a pin-shaft rotation mechanism 316; the cylinder piston rod connecting head fixing plate 319 is fixedly installed on the right-moving magnetic yoke mechanism 321; the magnetization clamping cylinder 320 is installed on the flaw detector frame 31; the left-moving magnetic yoke mechanism... The mechanism 314 and the right-moving magnetic yoke mechanism 321 are movably connected to the U-shaped fixed magnetic yoke mechanism 317 via the left and right guide wheel seats 315 and 318 installed on the front and rear sides of the U-shaped fixed magnetic yoke mechanism 317. The left and right moving magnetic yokes are closed by the left magnetic yoke rotation mechanism 313, the synchronous chain, the sprocket, and the magnetized clamping cylinder 320. The U-shaped fixed magnetic yoke mechanism 317 is mounted on the frame 31. The pin shaft rotation mechanism 316 is driven by a geared motor and is mounted on the flaw detector frame 31. like Figure 12As shown, the magnetic suspension spraying and recovery unit 34 includes a magnetic suspension storage tank, a pump motor, pipelines, valves, a spraying system with spray heads, and a magnetic suspension collection tank 32. The spray heads of the spraying system are installed on the flaw detector frame 31 to uniformly spray the magnetic suspension onto the surfaces of the buckle and cross pin. The magnetic suspension collection tank 32 is installed on the flaw detector frame 31 to collect the sprayed magnetic suspension and return it to the magnetic suspension tank for recycling. The magnetic suspension storage tank is made of 304 stainless steel non-magnetic material with a capacity of ≥60L to avoid magnetic suspension adsorption and sedimentation. The stirring method uses magnetic suspension reflux stirring, and the magnetic suspension is pumped out. The pump extracts the magnetic suspension from the bottom of the storage tank and returns it to the top, achieving uniform stirring and avoiding damage to the fluorescent magnetic powder by traditional stirring paddles. The spray head uses a new low-pressure, high-flow product, and each channel is equipped with a flow regulating valve to ensure that the magnetic suspension evenly covers the workpiece surface without splashing. The spray pressure is controlled at 0.1MPa~0.3MPa, and the flow rate is 5L / min~10L / min. The magnetic suspension collection tank 32 is located below the flaw detection station. The collected magnetic suspension is filtered through a filter screen (filtration accuracy 50μm) and then returned to the magnetic suspension storage tank for recycling. The magnetic suspension loss rate is ≤3% / day. The demagnetizing unit is used to eliminate residual magnetism left after magnetization of the shackle, preventing it from affecting subsequent use. The demagnetizing unit consists of a conveying device and a demagnetizing coil, employing a distance-based + automatic attenuation demagnetizing technology: the workpiece passes through the demagnetizing coil at a constant speed via the conveying device, and an alternating current with gradually decreasing amplitude is applied to the coil, generating a gradually weakening alternating magnetic field that disrupts the magnetic domains inside the shackle, ultimately achieving demagnetization. The demagnetizing coil uses an insulating epoxy board as its frame, is wound with double glass fiber, has 1000±50 turns, and an insulation resistance ≥10MΩ, ensuring safety and reliability. A work indicator light and video monitoring unit are installed on the side of the coil for easy observation of its working status. The demagnetizing current frequency can be adjusted within 50-500Hz, and the attenuation period can be set according to the workpiece specifications. After demagnetization, the overall residual magnetism of the workpiece is ≤3Gs, meeting the requirements of the NB / T47013.4-2015 standard.

[0025] The camera recognition mechanism 4 is set above the fluorescent magnetic particle inspection mechanism 3 via a truss. After the fluorescent magnetic particle inspection mechanism 3 performs inspection, the camera recognition mechanism 4 moves to the inspection station of the fluorescent magnetic particle inspection mechanism 3 to take a picture of the shackle. like Figures 18-20 As shown, the camera recognition mechanism 4 includes a button-type camera mechanism 45, a pin-type camera mechanism 45, and an industrial control computer; The buckle camera mechanism includes a rotating arm rotary cylinder 41 fixed to the crossbeam of the truss robotic arm, a rotating arm 42 connected to the output shaft of the rotating arm rotary cylinder 41, a camera rotary cylinder 43 connected to the other end of the rotating arm 42, and a buckle camera unit 44 connected to the output shaft of the camera rotary cylinder 43. The rotating arm rotary cylinder 41 drives the rotating arm 42 to rotate, thereby driving the buckle camera unit to reach above the buckle inspection station of the fluorescent magnetic particle inspection mechanism 3. The camera rotary cylinder 43 drives the buckle camera unit to rotate, thereby realizing the imaging of the buckle part. The buckle camera unit 44 includes a buckle camera frame connected to the output shaft of the camera rotary cylinder 43, and a high-definition camera and an ultraviolet lamp mounted on the buckle camera frame; The pin-type camera mechanism 45 includes a pin-type camera frame and a high-definition camera and an ultraviolet lamp mounted on the pin-type camera frame; the pin-type camera frame is located between the flaw detection host and the cleaning and drying mechanism.

[0026] The ultraviolet lamp is a fixed high-power LED ultraviolet lamp, used to provide ultraviolet light of suitable intensity and wavelength to excite the fluorescent magnetic powder to emit light, facilitating image acquisition by a high-definition camera; the ultraviolet lamp has a wavelength of 365nm and an intensity of ≥4000μW / cm² at a distance of 380mm from the workpiece surface. 2 To ensure that the fluorescent magnetic traces are clearly displayed; The high-definition camera is used to capture images of magnetic traces on the surface of the shackle. The high-definition camera is a megapixel high-definition industrial camera, equipped with a customized filter component to filter ambient light interference, and the image resolution is 4000×3000 pixels with a frame rate of ≥10fps to achieve fast shooting. The industrial control computer is equipped with AI semantic segmentation algorithm software, which is used to process and analyze the acquired images to achieve defect identification; the AI ​​semantic segmentation algorithm software is developed based on the library and editing software of commercially available software (Hikvision's VisionMaster); The specific method by which the AI ​​semantic segmentation algorithm software processes and analyzes the acquired images is as follows: S1. Image preprocessing: Denoising and enhancement processing of the acquired images to improve the contrast of fluorescent magnetic traces; S2, Threshold Segmentation: Set a fluorescence defect threshold to filter out suspected defect areas; S3. Feature Extraction: Analyze parameters such as continuity, length, width, and area of ​​suspected regions; S4. Defect Judgment: Based on the structural characteristics of the shackle, eliminate false defects (such as scratches and impurities) and determine whether it is a crack. S5. Information Recording: Mark the location, quantity, and size of cracks; identify the tonnage and number of shackles; and generate inspection reports by associating with test parameters.

[0027] The AI ​​semantic segmentation algorithm can achieve 100% recognition accuracy, with a single image processing time of ≤0.5 seconds, and supports data export and historical query.

[0028] The rinsing, air-drying and spraying mechanism realizes integrated cleaning and post-cleaning treatment. It includes a rinsing and air-drying mechanism 6, a spraying mechanism 8 and a hot air drying mechanism 7 arranged in sequence according to the process. The three are connected in an assembly line manner, equipped with automatic conveyor rollers and limit clamps, and adapted to shackles of different sizes. like Figures 21-23 As shown, the rinsing and drying mechanism 6 is used to rinse the shackles and remove residual moisture from the surface of the shackles after rinsing, thus creating conditions for the subsequent spraying process. like Figures 24-26 The hot air drying unit 7 shown is used for spray drying. It adopts a dual-path hot air circulation design, with a built-in adjustable speed centrifugal fan (wind speed adjustable from 0 to 5 m / s) and electric heating components. The hot air temperature is controlled between 40℃ and 60℃. The inclined air outlet forms a surrounding airflow, which fully covers the shackle surface and thread gaps, quickly removing residual moisture. The drying time is adjustable from 30s to 120s, and the surface moisture content of the workpiece after drying is ≤1%. like Figures 27-29 The spraying mechanism 8 shown is used to spray a protective coating on the surface of the shackle to improve its corrosion resistance. The spraying mechanism 8 is equipped with a high-precision quantitative spray gun and a 10L corrosion-resistant coating storage tank, which supports various media such as rust inhibitors and marking paints. The spray gun displacement and spraying time are controlled by the main controller, and the coating thickness is precisely controlled between 0.05mm and 0.2mm to ensure the rust prevention effect and coating uniformity. like Figures 21-23 As shown, the rinsing and drying mechanism 6 includes a water rinsing and drying unit 62, a H-shaped rinsing and drying frame 63, a lower rinsing water tank 64, multiple fixed rinsing nozzles 65 connected to the rinsing water tank 64 via pipelines, and a pulser 61 disposed on the outer side wall of the rinsing and drying frame 63; the fixed rinsing nozzles 65 are fixed to the bottom of the top beam of the rinsing and drying frame 63 by brackets, and the nozzles of the fixed rinsing nozzles 65 are aligned with the shackles; The pulsed compressed air generated by the pulse solenoid valve on the pulser 61 is connected to the nozzle of the water washing and drying unit 62 through a hose. The nozzle is aligned with the shackle, and the water washing and drying unit 62 blows air while moving to dry the moisture on the shackle. The water washing and drying unit 62 includes a drive mechanism, a moving guide rail, a nozzle and a nozzle bracket. The nozzle is installed on the nozzle bracket, and the nozzle bracket is connected to the output shaft of the drive mechanism. The drive mechanism drives the nozzle bracket to move on the moving guide rail.

[0029] like Figures 24-26As shown, the hot air drying mechanism 7 includes a hot air dryer frame 71, an electric heating hot air blower 74, and a liquid receiving tank 72 connected to the top beam of the hot air dryer frame 71; the electric heating hot air blower 74 is connected to the liquid receiving tank 72 through the hot air blower outlet pipe 73; a support net is provided in the liquid receiving tank 72, and the shackle is placed on the support net. like Figures 27-29 As shown, the spraying mechanism 8 includes a spraying frame 81, a spraying inner box 82, and a spraying cylinder 87 fixed to the top of the spraying frame 81 via a spraying cylinder fixing plate 88. The free end of the piston rod of the spraying cylinder 87 is connected to the spraying cylinder connecting plate 86, and the lower part of the spraying cylinder connecting plate 86 is connected to the spraying nozzle fixing frame 84. The lower part of the spraying nozzle fixing frame 84 is slidably connected to the spraying guide rail 89 fixed on the spraying frame 81 via a spraying slider 810. The spraying nozzle fixing frame 84 is U-shaped, and two spraying nozzles 83 are respectively fixed to the two free ends of the spraying nozzle fixing frame 84, and the two spraying nozzles 83 are respectively located on the upper and lower sides of the shackle. The spraying inner box 82 is located on the upper part of the spraying frame 81, and all other components of the spraying mechanism 8 except the spraying frame 81 are located above the spraying inner box 82.

[0030] The six-axis robotic arm handling mechanism includes at least two six-axis robotic arms 10 and a shackle clamp provided at the free end of the six-axis robotic arm 10; The six-axis robotic arm 10 is used to accurately and flexibly transport intelligent shackles between different workstations, realizing the automated flow of shackles between various inspection processes. The six-axis robotic arm 10 has six degrees of freedom, enabling it to accurately and flexibly transport intelligent shackles between different workstations, realizing the automated flow of shackles between various inspection processes. It has high motion precision and strong load capacity, and can adapt to the handling needs of shackles of different specifications, ensuring the smooth progress of the entire inspection process and greatly improving production efficiency and inspection accuracy. The six-axis robotic arm 10 is a conventional commercially available device. The shackle clamp includes a shackle loading clamp 11 and a shackle unloading clamp 12; like Figures 30-32 As shown, the shackle loading clamp 11 includes an upper clamp upper support plate 111, an upper clamp lower support plate 112, an upper clamp slide rail 113, an upper clamp side connecting plate 1110, an upper clamp rear connecting plate 1115, an upper clamp clamping cylinder 115, an upper clamp left clamping claw 117, an upper clamp right clamping claw 118, an upper clamp claw sliding seat 119, an upper clamp synchronous gear 1114, and an upper clamp synchronous rack 1112; The upper clamp slide rail 113 is disposed on the top of the upper clamp lower support plate 112; The upper clamp synchronous gear 1114 is mounted on the middle part of the upper clamp lower support plate 112 via the upper clamp gear seat 1113; The upper clamp upper support plate 111 and the lower clamp lower support plate 112 are arranged parallel to each other vertically. The upper clamp side connecting plate 1110 and the upper clamp rear connecting plate 1115 are arranged parallel to each other and are both located between the upper clamp upper support plate 111 and the upper clamp lower support plate 112. Both ends of the upper clamp are connected to the upper clamp upper support plate 111 and the upper clamp lower support plate 112 respectively. The upper clamp rear connecting plate 1115 is connected to the six-axis robotic arm. The upper clamp upper support plate 111, the upper clamp lower support plate 112, the upper clamp side connecting plate 1110 and the upper clamp rear connecting plate 1115 form the basic frame structure of the shackle loading clamp 11. The upper clamping cylinder 115 is mounted on the upper clamping plate 111 via the upper clamping cylinder seat 114. The free end of the piston of the upper clamping cylinder 115 is connected to the upper clamping jaw sliding seat 119. The bottom of the upper clamping jaw sliding seat 119 is connected to the upper clamping right clamping jaw 118. The upper clamping left clamping jaw 117 and the upper clamping right clamping jaw 118 are both slidably connected to the upper clamping slide rail 113 via the upper clamping slider 116. The rear ends of the upper clamping left clamping jaw 117 and the upper clamping right clamping jaw 118 are both provided with upper clamping synchronous racks 1112. The upper clamping synchronous racks 1112 at the rear ends of the upper clamping left clamping jaw 117 and the upper clamping right clamping jaw 118 are distributed on both sides of the upper clamping synchronous gear 1114, and both are meshed with the upper clamping synchronous gear 1114. like Figures 33-35 As shown, the shackle unloading fixture 12 includes a lower fixture lower support plate 121, a lower fixture upper support plate 122, a lower fixture side connecting plate 1210, a lower fixture rear connecting plate 1216, a lower fixture clamping cylinder 125, a lower fixture left clamping claw 127, a lower fixture right clamping claw 128, a lower fixture claw sliding seat 129, a lower fixture synchronous gear 1215, and a lower fixture synchronous rack 1213; The lower clamp slide rail 123 is disposed on the top of the lower clamp support plate 121; The lower clamp synchronous gear 1215 is mounted on the middle part of the lower clamp lower support plate 121 via the lower clamp gear seat 1214; The lower clamp upper support plate 122 and the lower clamp lower support plate 121 are arranged parallel to each other vertically. The lower clamp side connecting plate 1210 and the lower clamp rear connecting plate 1216 are arranged parallel to each other, and both are located between the lower clamp upper support plate 122 and the lower clamp lower support plate 121. Both ends of the lower clamp are connected to the lower clamp upper support plate 122 and the lower clamp lower support plate 121, respectively. The lower clamp rear connecting plate 1216 is connected to the six-axis robotic arm. The lower clamp lower support plate 121, the lower clamp upper support plate 122, the lower clamp side connecting plate 1210 and the lower clamp rear connecting plate 1216 form the basic frame structure of the shackle unloading clamp 12. The lower clamping cylinder 125 is mounted on the upper support plate 122 of the lower clamp via the lower clamping cylinder seat 124. The free end of the piston of the lower clamping cylinder 125 is connected to the lower clamping claw sliding seat 129. The bottom of the lower clamping claw sliding seat 129 is connected to the lower clamping right clamping claw 128. The lower clamping left clamping claw 127 and the lower clamping right clamping claw 128 are both slidably connected to the lower clamping slide rail 123 via the lower clamping slider 126. The lower clamping left clamping claw 127 and the lower clamping right clamping claw 128 are both provided with a lower clamping synchronous rack 1213 at their rear ends. The lower clamping synchronous racks 1213 at the rear ends of the lower clamping left clamping claw 127 and the lower clamping right clamping claw 128 are distributed on both sides of the lower clamping synchronous gear 1215, and both of them mesh with the lower clamping synchronous gear 1215. The storage box 9 is used to store the shackles after inspection is completed; The main controller includes a PLC and a human-machine interface. It uses the PLC as the control core and the human-machine interface to realize the linkage control and parameter setting of each mechanism. The main controller uses a Siemens S7-1200 PLC, which is responsible for performing logic operations and issuing control commands to achieve multi-process linkage. The human-machine interface uses a 10-inch industrial touch screen to display the equipment's operating status in real time (such as the working progress of each module, the number of tests, and fault information), and supports parameter settings (cleaning power / duration, magnetizing current / time, demagnetizing frequency, air drying temperature / time, spraying dosage, etc.). The circuit system connecting the main controller and various mechanisms is installed using a 35mm standard DIN rail. The main circuit includes an air switch, AC contactor, and synchronous power transformer, while the control circuit includes intermediate relays, protective circuit breakers, and motor protection circuit breakers. The layout is neat and easy to maintain. Safety protection mechanisms include: emergency stop buttons for each module, safety door limit switches (stopping the machine when the door is opened), overload protection (power-off alarm when motor current exceeds the limit), and short circuit / leakage protection (tripping when leakage current ≥ 30mA). Process linkage is achieved through photoelectric sensors. The next process cannot start if the previous process is not completed, thus avoiding process confusion.

[0031] Example 2

[0032] A smart shackle integrated fluorescent magnetic particle flaw detection method includes the following steps: S1. Place the shackle on the feeding platform mechanism, and the feeding platform mechanism will transport the shackle in an orderly manner to the ultrasonic cleaning mechanism before flaw detection of the dual-station ultrasonic cleaning mechanism. During the conveying process, the feeding platform mechanism 1 maintains stable operation to ensure that the shackle is positioned accurately; S2. Before flaw detection, the ultrasonic cleaning mechanism cleans the shackles using the high-frequency ultrasonic cavitation effect. The cleaning power and duration are adjusted according to the degree of dirt on the shackles to remove oil, dust and other impurities from the shackle surface. According to the degree of dirt on the shackle, the operator adjusts the cleaning power and duration through the main controller. During the cleaning process, high-frequency ultrasonic waves generate a large number of microbubbles in the cleaning fluid. The impact force and microjet formed by the bursting of the bubbles penetrate into the tiny gaps on the shackle surface, effectively removing impurities such as oil and dust. After cleaning, the shackle surface is clean and tidy, ready for subsequent magnetic particle inspection.

[0033] S3, the six-axis robotic arm transport mechanism transports the cleaned shackles from the ultrasonic cleaning mechanism before flaw detection to the fluorescent magnetic particle flaw detection mechanism. During the handling process, the six-axis robotic arm 10 maintains stable movement to ensure the accurate position and posture of the shackle and avoid damage to the shackle.

[0034] S4. Based on the shape and size of the shackle, select an appropriate magnetization method. Apply a magnetic field to the shackle through the shackle body magnetization unit and the pin magnetization unit. At the same time, the magnetic suspension spray recovery system sprays the magnetic suspension evenly on the shackle surface, so that the defect area generates a leakage magnetic field and attracts magnetic powder to form magnetic traces, so as to clearly show the location and shape of the defect.

[0035] S5. The ultraviolet lamp of the camera recognition mechanism provides ultraviolet light to excite the fluorescent magnetic powder to emit light. The high-definition camera captures the magnetic trace image on the surface of the shackle. The industrial control computer uses the point-by-point scanning color gradation method and AI semantic segmentation algorithm to process the image, automatically identify crack defects, extract parameters such as the number, coordinate position and length of cracks, and identify the identification information of the shackle tonnage and number, and generate an inspection report. S6. The demagnetizing mechanism of the fluorescent magnetic particle inspection system adopts a distance + automatic attenuation demagnetizing technology to demagnetize the shackle. The demagnetizing coil generates a uniform demagnetizing magnetic field to eliminate residual magnetism on the shackle, so that the overall residual magnetism of the parts after demagnetization is ≤3Gs, ensuring that the shackle will not affect subsequent use due to residual magnetism.

[0036] S7, the six-axis robotic arm transport mechanism transports the demagnetized shackle to the ultrasonic cleaning mechanism after flaw detection in the dual-station ultrasonic cleaning mechanism. During the handling process, the six-axis robotic arm 10 once again ensured that the position and posture of the shackles were accurate, preparing for the subsequent cleaning work.

[0037] S8. After flaw detection, the ultrasonic cleaning mechanism cleans the shackle again through high-frequency ultrasonic cavitation effect to remove the residual magnetic suspension on the shackle surface. Operators can adjust the cleaning parameters according to the actual situation to ensure the cleaning effect.

[0038] S9. The air-drying module of the air-drying spraying mechanism adjusts the temperature and air-drying time according to the material and size of the shackle to air-dry the shackle, remove surface moisture, and create good conditions for the subsequent spraying process. S10. The spraying module of the air-drying spraying mechanism uses a high-precision quantitative spray gun to spray a protective coating on the shackle surface according to the set coating thickness. Operators can precisely control the spraying amount and speed of the spray gun through the control system to ensure uniform coating thickness and improve coating quality and performance.

[0039] S11, the six-axis robotic arm handling mechanism transports the inspected and processed shackles to the storage box, completing the entire inspection process.

[0040] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and 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, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0041] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0042] The applicant declares that the above description is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention fall within the protection and disclosure scope of the present invention.

Claims

1. An integrated intelligent shackle fluorescent magnetic particle flaw detection device, characterized in that: include: The feeding platform mechanism (1) is used to transport the shackles to be inspected to the subsequent processing station; A dual-station ultrasonic cleaning system is used for cleaning shackles to be inspected before and after flaw detection. Fluorescent magnetic particle inspection mechanism (3), which is used to display the location and shape of defects in the shackle to be inspected; The camera recognition mechanism (4) is used to collect images of the shackles to be inspected; The rinsing, air-drying, and spraying mechanism is used for air-drying and spraying treatment of the unfastened parts after inspection. Storage box (8), which is used to store shackles after inspection; A six-axis robotic arm handling mechanism used for handling shackles; The main controller is used for the coordinated control between various mechanisms.

2. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 1, characterized in that: The feeding platform mechanism (1) includes a feeding platform (11), a drive mechanism, and a shackle tray (12); the drive mechanism includes a geared motor (13), a sprocket assembly, and a chain (14); the geared motor (13) is mounted on the feeding platform mechanism (1) via a motor mounting bracket (19); the chain (14) is wound around the sprocket assembly and meshes with it; the sprocket assembly includes a drive sprocket (15), a tensioning wheel assembly, and a transition wheel (17) arranged sequentially along the transmission direction; the drive sprocket (15) is mounted on the drive shaft of the geared motor (13); the tensioning wheel assembly is mounted on the drive shaft of the geared motor (13); the tensioning wheel assembly is mounted on the drive shaft of the geared motor (13). The tension wheel fixing frame (16) is set on the feeding platform mechanism (1); the transition wheel (17) is set on the feeding platform mechanism (1) through the transition wheel fixing frame (18); the shackle tray (12) includes a tray, two support beams set on the tray, a transmission wheel set on the bottom of the tray, and a chain connecting ear (110) set on the bottom of the tray; the transmission wheel meshes with the chain (14), and the chain connecting ear (110) is connected to the chain (14); one support beam is used to place the buckle body part after the shackle is disassembled; the other support beam is used to place the pin part after the shackle is disassembled.

3. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 1, characterized in that: The dual-station ultrasonic cleaning mechanism includes a pre-detection ultrasonic cleaning mechanism (2) located between the feeding platform mechanism (1) and the fluorescent magnetic particle flaw detection mechanism (3), and a post-detection ultrasonic cleaning mechanism (5) located between the camera recognition mechanism (4) and the air drying module (6) of the air drying spraying mechanism. The ultrasonic cleaning mechanism (2) before flaw detection and the ultrasonic cleaning mechanism (5) after flaw detection have the same structure, both including a shell (21) and a cleaning tank (22), a filter water tank (26) and a self-priming pump (29) set inside the shell; the self-priming pump (29) is connected to the cleaning tank (22) through a water supply pipe (25), and a pre-filter (24) is set on the water supply pipe (25); the inlet of the self-priming pump (29) is connected to the filter water tank (26) through a pipeline; multiple ultrasonic transducers (23) are set at the bottom of the cleaning tank (22); an electric heating tube (28) and a temperature sensor (27) are set inside the filter water tank (26).

4. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 1, characterized in that: The fluorescent magnetic particle flaw detection mechanism (3) includes a flaw detection frame (31), a magnetization unit, a magnetic suspension spraying and recovery unit (34), and a demagnetization unit installed on the flaw detection frame (31).

5. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 4, characterized in that: The magnetization unit includes a buckle magnetization unit (33) and a pin magnetization unit (35); the magnetization unit uses independently set circumferential magnetization transformer (36) and longitudinal magnetization transformer (37) as magnetization power sources; The button magnetization unit mechanism (33) includes a yoke moving mechanism (38), a rod-through yoke closing mechanism (39), a rod-through yoke repositioning mechanism (310), a button placement platform (311), and a lower yoke (312). The rod-through yoke repositioning mechanism (310) is mounted on the side of the rod-through yoke closing mechanism (39) via a rotating shaft. The other side of the rod-through yoke closing mechanism (39) is slidably connected to a guide rail mounted on the side of the yoke moving mechanism (38) via a slider. The closing and opening of the rod-through yoke is achieved by a closing cylinder. The yoke moving mechanism (38) is slidably connected to a guide rail mounted on the flaw detector frame (31) via a lower slider. The movement of the moving yoke is achieved by a moving cylinder. The lower yoke (312) and the button placement platform (311) are also included. The pin-shaft magnetization unit mechanism (35) includes a left-moving magnetic yoke mechanism (314), a right-moving magnetic yoke mechanism (321), a left magnetic yoke rotation mechanism (313), a U-shaped fixed magnetic yoke mechanism (317), and a pin-shaft rotation mechanism (316). The left-moving magnetic yoke mechanism (314) and the right-moving magnetic yoke mechanism (321) are movably connected to the U-shaped fixed magnetic yoke mechanism (317) by left and right guide wheel seat plates (315, 318) installed on the front and rear sides of the U-shaped fixed magnetic yoke mechanism (317). The left and right moving magnetic yokes are closed by the left magnetic yoke rotation mechanism (313), synchronous chain, sprocket, and magnetization clamping cylinder (320). The U-shaped fixed magnetic yoke mechanism (317) is installed on the frame (31). The pin-shaft rotation mechanism (316) is driven by a geared motor and is installed on the flaw detector frame (31). The magnetic suspension spray recovery unit (34) includes a magnetic suspension storage tank, a pump motor, pipelines, valves, a spray system with spray heads, and a magnetic suspension collection tank (32). The spray heads of the spray system are installed on the flaw detector frame (31) and are used to spray the magnetic suspension evenly on the surface of the buckle and the cross pin. The magnetic suspension collection tank (32) is installed on the flaw detector frame (31) and is used to collect the sprayed magnetic suspension and send it back to the magnetic suspension tank. The magnetic suspension collection tank (32) is located below the flaw detection station.

6. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 4, characterized in that: The demagnetizing unit is used to eliminate residual magnetism left after the shackle is magnetized; the demagnetizing unit consists of a conveying device and a demagnetizing coil; the demagnetizing coil is made of insulating epoxy board as skeleton, double glass wire wrapped with wire, 1000±50 turns, and insulation resistance ≥10MΩ.

7. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 1, characterized in that: The camera recognition mechanism (4) includes a buckle camera mechanism and a pin camera mechanism (45); The buckle body camera mechanism includes a rotating arm rotating cylinder (41) fixed to the crossbeam of the truss manipulator, a rotating arm (42) connected to the output shaft of the rotating arm rotating cylinder (41), a camera rotating cylinder (43) connected to the other end of the rotating arm (42), and a buckle body camera unit (44) connected to the output shaft of the camera rotating cylinder (43); the buckle body camera unit (44) includes a buckle body camera frame connected to the output shaft of the camera rotating cylinder (43), and a high-definition camera and an ultraviolet lamp installed on the buckle body camera frame. The pin body camera mechanism (45) includes a pin body camera frame, and a high-definition camera and an ultraviolet lamp installed on the pin body camera frame; the pin body camera frame is arranged at the middle position between the flaw detection host and the cleaning and air drying mechanism.

8. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 1, characterized in that: The flushing, air drying and spraying mechanism includes a flushing and air drying mechanism (6), a spraying mechanism (8) and a hot air drying mechanism (7) arranged in sequence according to the process. The flushing and air drying mechanism (6) includes a water washing and air drying unit (62), a day-shaped flushing and air drying frame (63), a flushing water tank (64) at the lower layer, a plurality of fixed flushing nozzles (65) connected to the flushing water tank (64) through pipelines, and a pulsator (61) arranged on the outer side wall of the flushing and air drying frame (63); the fixed flushing nozzles (65) are fixed to the lower part of the top beam of the flushing and air drying frame (nozzles (65) are fixed to the lower part of the top beam of the flushing and air drying frame (63) through brackets, and the nozzles of the fixed flushing nozzles (65) are aligned with the shackles; the pulsed compressed air formed by the pulsed solenoid valve on the pulsator (61) is connected to the nozzle of the water washing and air drying unit (62) through a hose, and the nozzle is aligned with the shackle. The water washing and air drying unit (62) blows air while moving to dry the water on the shackle; the water washing and air drying unit (62) includes a driving mechanism, a moving guide rail, a nozzle and a nozzle bracket. The nozzle is installed on the nozzle bracket, and the nozzle bracket is connected to the output shaft of the driving mechanism. The driving mechanism drives the nozzle bracket to move on the moving guide rail. The hot air drying mechanism (7) includes a hot air drying frame (71), an electric heating hot air blower (74), and a liquid receiving tank (72) connected to the top beam of the hot air drying frame (71); the electric heating hot air blower (74) is communicated with the liquid receiving tank (72) through a hot air blower outlet pipe (73); a support net is arranged in the liquid receiving tank (72), and the shackle is placed on the support net. The spraying mechanism (8) includes a spraying frame (81), a spraying inner box (82), and a spraying cylinder (87) fixed to the top of the spraying frame (81) via a spraying cylinder fixing plate (88). The free end of the piston rod of the spraying cylinder (87) is connected to the spraying cylinder connecting plate (86), and the lower part of the spraying cylinder connecting plate (86) is connected to the spraying nozzle fixing bracket (84). The lower part of the spraying nozzle fixing bracket (84) is connected to the spraying nozzle fixing bracket (84) via a spraying slider (810). The spraying guide rail (89) on the spraying frame (81) is slidably connected; the spraying nozzle fixing bracket (84) is U-shaped, and the two spraying nozzles (83) are respectively fixed to the two free ends of the spraying nozzle fixing bracket (84), and the two spraying nozzles (83) are respectively located on the upper and lower sides of the shackle; the spraying inner box (82) is set on the upper part of the spraying frame (81), and except for the spraying frame (81), the other components of the spraying mechanism (8) are all located above the spraying inner box (82).

9. The intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to claim 1, characterized in that: The six-axis robotic arm handling mechanism includes at least two six-axis robotic arms (10) and a shackle clamp provided at the free end of the six-axis robotic arm (10); the shackle clamp includes a shackle loading clamp (11) and a shackle unloading clamp (12). The shackle loading fixture (11) includes an upper clamp upper support plate (111), an upper clamp lower support plate (112), an upper clamp slide rail (113), an upper clamp side connecting plate (1110), an upper clamp rear connecting plate (1115), an upper clamp clamping cylinder (115), an upper clamp left clamping claw (117), an upper clamp right clamping claw (118), an upper clamping claw sliding seat (119), an upper clamp synchronous gear (1114), and an upper clamp synchronous rack (1112). The upper clamp slide rail (113) is located on the top of the upper clamp lower support plate (112); the upper clamp synchronous gear (1114) is installed in the middle of the upper clamp lower support plate (112) through the upper clamp gear seat (1113); the upper clamp upper support plate (111) and the upper clamp lower support plate (112) are arranged parallel to each other vertically, the upper clamp side connecting plate (1110) and the upper clamp rear connecting plate (1115) are arranged parallel to each other, and both are located between the upper clamp upper support plate (111) and the upper clamp lower support plate (112), and both ends are connected to the upper clamp upper support plate (111) and the upper clamp lower support plate (112) respectively; the upper clamp rear connecting plate (1115) is connected to the six-axis robotic arm; the upper clamp clamping cylinder (115) is installed through the upper clamp cylinder seat (114). On the upper support plate (111) of the upper clamp, the free end of the piston of the upper clamp clamping cylinder (115) is connected to the upper clamp jaw sliding seat (119), and the bottom of the upper clamp jaw sliding seat (119) is connected to the upper clamp right clamping jaw (118); the upper clamp left clamping jaw (117) and the upper clamp right clamping jaw (118) are both slidably connected to the upper clamp slide rail (113) through the upper clamp slider (116); the upper clamp left clamping jaw (117) and the upper clamp right clamping jaw (118) are both provided with upper clamp synchronous racks (1112) at their rear ends, and the upper clamp synchronous racks (1112) at the rear ends of the upper clamp left clamping jaw (117) and the upper clamp right clamping jaw (118) are distributed on both sides of the upper clamp synchronous gear (1114), and both are meshed with the upper clamp synchronous gear (1114); The shackle unloading clamp (12) includes a lower clamp support plate (121), an upper clamp support plate (122), a side connecting plate (1210), a rear connecting plate (1216), a clamping cylinder (125), a left clamping jaw (127), a right clamping jaw (128), a jaw sliding seat (129), a synchronizing gear (1215), and a synchronizing rack (1213); the lower clamp slide rail (123) is located on the lower clamp. The top of the support plate (121); the lower clamp synchronous gear (1215) is installed in the middle of the lower clamp lower support plate (121) via the lower clamp gear seat (1214); the lower clamp upper support plate (122) and the lower clamp lower support plate (121) are arranged parallel to each other vertically, the lower clamp side connecting plate (1210) and the lower clamp rear connecting plate (1216) are arranged parallel to each other, and both are located between the lower clamp upper support plate (122) and the lower clamp lower support plate (121), and both ends are respectively connected to the lower clamp. The upper support plate (122) and the lower clamp lower support plate (121) are connected; the lower clamp rear connecting plate (1216) is connected to the six-axis robotic arm; the lower clamp clamping cylinder (125) is mounted on the lower clamp upper support plate (122) through the lower clamp cylinder seat (124), the piston free end of the lower clamp clamping cylinder (125) is connected to the lower clamp jaw sliding seat (129), and the bottom of the lower clamp jaw sliding seat (129) is connected to the lower clamp right clamping jaw (128); the lower clamp left clamping jaw (127) and the lower clamp... The right clamping jaw (128) of the clamp is slidably connected to the lower clamping slide rail (123) via the lower clamping slider (126); the rear ends of the left clamping jaw (127) and the right clamping jaw (128) of the lower clamp are provided with lower clamping synchronous racks (1213). The lower clamping synchronous racks (1213) at the rear ends of the left clamping jaw (127) and the right clamping jaw (128) of the lower clamp are distributed on both sides of the lower clamping synchronous gear (1215), and both of them mesh with the lower clamping synchronous gear (1215).

10. An inspection method based on the intelligent shackle fluorescent magnetic particle flaw detection integrated inspection device according to any one of claims 1 to 9, characterized in that: Includes the following steps: S1. Place the shackle on the feeding platform mechanism, and the feeding platform mechanism will transport the shackle to the ultrasonic cleaning mechanism before flaw detection of the dual-station ultrasonic cleaning mechanism. S2. The ultrasonic cleaning mechanism cleans the shackles before flaw detection. S3, the six-axis robotic arm transport mechanism transports the cleaned shackles from the ultrasonic cleaning mechanism before flaw detection to the fluorescent magnetic particle flaw detection mechanism. S4. Select a suitable magnetization method according to the shape and size of the shackle. Apply a magnetic field to the shackle through the shackle body magnetization unit and the pin magnetization unit. At the same time, the magnetic suspension spraying and recovery system sprays the magnetic suspension evenly on the surface of the shackle. S5. The ultraviolet lamp of the camera recognition mechanism provides ultraviolet light to excite the fluorescent magnetic powder to emit light. The high-definition camera captures the magnetic trace image on the surface of the shackle. The industrial control computer uses the point-by-point scanning color gradation method and AI semantic segmentation algorithm to process the image, automatically identify crack defects, extract parameters such as the number, coordinate position and length of cracks, and identify the identification information of the shackle tonnage and number, and generate an inspection report. S6. The demagnetizing mechanism of the fluorescent magnetic particle inspection system adopts a remote combined automatic attenuation demagnetizing technology to demagnetize the shackles. S7, the six-axis robotic arm transport mechanism transports the demagnetized shackle to the ultrasonic cleaning mechanism after flaw detection in the dual-station ultrasonic cleaning mechanism. S8. After flaw detection, the shackle is cleaned again by the ultrasonic cleaning mechanism. S9. The air-drying module of the air-drying spraying mechanism performs air-drying treatment on the shackles; S10, The spraying module of the air-drying spraying mechanism sprays a protective coating onto the surface of the shackle; S11, the six-axis robotic arm handling mechanism transports the inspected and processed shackles to the storage box, completing the entire inspection process.

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