Seven-axis robot-based automatic head flaw detection collaborative control system and method

Abstract

This application discloses a collaborative control system and method for automatic flaw detection of end caps based on a seven-axis robot, relating to the field of automatic flaw detection technology. The system includes a base plate, an operating table, and a seven-axis robot. The operating table is equipped with at least three limiting mechanisms evenly distributed along the circumference. Each limiting mechanism includes a limiting seat, a first drive assembly, a second drive assembly, a first wheel set, a lifting component, and a second wheel set, along with a flaw detection execution and communication control unit. The method covers the steps of end cap loading and positioning, centering and clamping, system networking, flaw detection linkage execution, data acquisition and feedback, and intelligent control of the entire process. This solution can be adapted to end caps of different specifications, achieving collaborative linkage between centering and clamping, rotation drive, and seven-axis robot flaw detection, significantly improving the automation level, detection accuracy, and operational efficiency of end cap flaw detection.

Description

Technical Field

[0001] This application relates to the field of automatic flaw detection system technology, specifically to a collaborative control system and method for automatic flaw detection of end caps based on a seven-axis robot. Background Technology

[0002] End caps are core pressure-bearing components of pressure vessels, boilers, nuclear power equipment, and other pressure-bearing equipment. The quality of their welds directly determines the operational safety of the equipment throughout its entire lifecycle. Ultrasonic testing is the mainstream technology for detecting internal defects in end cap welds. With the rapid development of the high-end equipment manufacturing industry, higher requirements are being placed on the automation level, detection accuracy, and operational efficiency of end cap testing.

[0003] Currently, most end cap flaw detection equipment uses fixed clamping fixtures in conjunction with multi-axis robotic arms to perform inspection operations. For example, Chinese utility model patent with publication number CN218766724U discloses an end cap flaw detection device that uses a fixed clamping mechanism to position the end cap and uses a robotic arm to drive the flaw detector to complete the weld inspection operation.

[0004] The aforementioned existing technology suffers from a core technical defect: the clamping mechanism is a fixed structure, which cannot adapt to heads of different diameters and curved surface specifications. It is difficult to achieve precise centering and stable rotation drive of the head, resulting in poor coordination between the robotic arm's flaw detection actions and the head's rotation. This leads to trajectory tracking deviations during the inspection process, reducing both inspection accuracy and result consistency, and significantly limiting the equipment's adaptability and operational efficiency. Consequently, it cannot meet the demand for efficient automated flaw detection of large batches of heads of various specifications. Summary of the Invention

[0006] Therefore, this application provides a collaborative control system and method for automatic flaw detection of end caps based on a seven-axis robot, in order to solve the problems existing in the prior art.

[0007] To achieve the above objectives, this application provides the following technical solution: Firstly, a collaborative control system for automatic flaw detection of end caps based on a seven-axis robot includes a base plate, an operating platform, and the seven-axis robot. The operating platform is mounted on the base plate, and the seven-axis robot is mounted on the base plate on one side of the operating platform. It also includes at least three limiting mechanisms, evenly spaced and distributed circumferentially on the operating platform. The limiting mechanisms include: The limiting seat has first guide rails symmetrically arranged on both sides of the top along the length direction, and a guide groove is opened through the side wall below the first guide rail. The limiting seat has external plates symmetrically arranged on both sides of the bottom, and a second guide rail is arranged on the top surface of the external plates parallel to the first guide rail. The first drive assembly is located on top of the limit seat, between the two first guide rails; The second drive component is located at the bottom of the limit seat, between the two guide grooves; The first wheel assembly is located at the drive end of the first drive component, and a portion of the first wheel assembly is slidably connected to the first guide rail. The lifting component is located at the drive end of the second drive assembly and on the side of the first wheel set away from the center of the circular array of multiple limit mechanisms. The second set is installed on the lifting end of the lifting component.

[0008] Optionally, the base plate is also provided with a flaw detection guide rail, which is set on the base plate in a vertical direction perpendicular to the line connecting the seven-axis robot and the operating table; a movable base is slidably connected to the flaw detection guide rail; wherein, the seven-axis robot is mounted on the movable base, and a flaw detector is installed at the end of the seven-axis robot away from the movable base.

[0009] Optionally, the first drive assembly includes a first drive rod rotatably connected to a limiting seat along a path parallel to the first guide rail; a first drive disc coaxially connected to one end of the first drive rod near the lifting member; a first slider sleeved on the first drive rod; a first slide block mounted on the top of the first slider and slidably connected to the first guide rail on both sides of its bottom; and a first wheel set disposed on the first slide block.

[0010] Optionally, the second drive assembly includes a second drive rod rotatably connected to the limiting seat along a direction parallel to the length of the guide groove; a second drive disc coaxially connected to one end of the second drive rod near the first drive disc; a second slider sleeved on the second drive rod; a second slide block mounted on the top of the second slider, with both ends passing through the guide grooves on both sides and slidably connected to the second guide rail; and a lifting component mounted on the portion of the second slide block extending out of the guide groove.

[0011] Optionally, the lifting component includes a lifting mounting base mounted on a second slide block, with symmetrical lifting slots on both sides of the lifting mounting base, and a connecting plate at the bottom of one of the lifting slots; multiple lifting guide rails symmetrically and slidably connected to the lifting mounting base, with two lifting guide rails on the same side connected by a connecting block, and the other side of the connecting base slidably connected in the lifting slot; a lifting seat connected to the top of the corresponding lifting guide rails on both sides, with a second wheel set mounted on the lifting seat; a lifting rod passing through the connecting plate and slidably connected to the connecting plate, with one end connected to the lifting seat and the other end extending freely downwards; and a drive unit mounted on the connecting plate to provide lifting driving force for the lifting rod.

[0012] Optionally, the first slide is tilted, and the first wheel assembly is mounted on the tilted surface of the first slide.

[0013] Optionally, the first wheel assembly includes a bracket base plate disposed on the inclined surface of the first slide and parallel to the inclined surface; a support plate rotatably connected to the higher end of the bracket base plate; a first support wheel rotatably connected to the support plate, and the axial direction of the first support wheel forms an angle with the length direction of the first drive rod; and a first drive motor coaxially connected to the first support wheel and mounted on the support plate.

[0014] Optionally, the second wheel set includes an adjusting shaft that extends through the lifting seat along a length direction parallel to the second drive rod; a mounting bracket located on the side of the adjusting shaft near the first wheel set; a second support wheel that is rotatably connected to the mounting bracket on the side near the first wheel set; and a buffer spring that is sleeved on the adjusting shaft and located between the mounting bracket and the lifting seat.

[0015] Optionally, it also includes a material support component, which includes a conveying rod; a hinge joint located at one end of the conveying rod; and a material support plate rotatably connected to the end of the hinge joint away from the conveying rod.

[0016] Secondly, a method for automatic flaw detection of end caps based on a seven-axis robot, and a collaborative control system for automatic flaw detection of end caps based on a seven-axis robot as described above, includes the following steps: S1: The operator places the end cap to be tested onto the multiple limit mechanisms on the operating table through the material dragging component. The system detects and confirms that the end cap is placed stably in place. S2: According to the diameter specifications of the end cap to be tested, the positions of the first wheel group and the second wheel group are adjusted by the first drive component, the second drive component and the lifting component to complete the centering clamping and rotation limit of the end cap; S3: Through the independent power supply and gateway wireless communication module of the rotating tooling, the device nodes are automatically refreshed within the local area network, and a two-way communication connection is established with the seven-axis robot, flaw detector, flaw detection reflector and host computer to build a closed-loop collaborative control system. S4: The host computer issues a flaw detection execution command, controls the mobile base to move along the flaw detection guide rail to the preset detection station, and the seven-axis robot carries the flaw detector to the detection start position corresponding to the end cap weld. Simultaneously, the flaw detection reflector is controlled to move to the corresponding detection position that matches the flaw detector. S5: Control the first support wheel of the first wheel group to drive the end cap to rotate smoothly at a preset speed. At the same time, the seven-axis robot drives the flaw detector to follow the spatial trajectory of the end cap weld in real time, collect the flaw detection data of the end cap weld in real time, and feed the collected data back to the host computer in real time. S6: The system collects the position information and operating status data of each execution unit in real time and feeds them back to the host computer. The execution master control program performs real-time calibration and anomaly control on the linkage timing and operating parameters of each unit. After the full circumference weld flaw detection of the head is completed, all execution units are reset to the initial position and the system waits for the next inspection cycle.

[0017] Compared with the prior art, this application has at least the following beneficial effects: 1. Through multiple sets of limiting mechanisms distributed in a circular array, combined with the horizontally adjustable first and second wheel sets and the vertically adjustable lifting components, it can adapt to end caps of different diameters and curved surface specifications, achieving precise centering and clamping and stable rotational limiting of the end caps. This fundamentally solves the problems of poor adaptability and insufficient centering accuracy of existing equipment, providing a stable operating foundation for automated flaw detection.

[0018] 2. By using a movable seven-axis robot with a flaw detector, and in conjunction with the self-driven first wheel assembly structure, the rotation of the end cap and the flaw detection action of the seven-axis robot can be precisely coordinated and linked, eliminating trajectory tracking deviations during the detection process, greatly improving the detection accuracy and consistency of weld flaw detection, and avoiding the problems of missed detection and false detection.

[0019] 3. By using a second wheel assembly with a buffer structure, an adaptive adjustable support wheel structure, and a convenient material support component, the ease of operation and stability of the equipment are improved. At the same time, a closed-loop communication and collaborative control system is provided to realize the full-process automated control of feeding, positioning, detection, and unloading, which greatly reduces the intensity of manual operation and meets the needs of continuous flaw detection operations for large batches of end caps. Attached Figure Description

[0020] To more intuitively illustrate the prior art and this application, exemplary drawings are provided below. It should be understood that the specific shapes and structures shown in the drawings should not generally be regarded as limiting conditions for implementing this application; for example, based on the technical concept disclosed in this application and the exemplary drawings, those skilled in the art are able to easily make conventional adjustments or further optimizations to the addition / reduction / classification, specific shapes, positional relationships, connection methods, size ratios, etc. of certain units (components).

[0021] Figure 1 A three-dimensional structural diagram of the collaborative control system for automatic flaw detection of end caps based on a seven-axis robot provided in an embodiment of this application; Figure 2 This is a schematic diagram of the overall structure of the limiting mechanism provided in the embodiments of this application; Figure 3 This is a schematic diagram of the structure of the material support provided in the embodiments of this application; Figure 4 This is an enlarged structural diagram of the first drive component and the first wheel assembly; Figure 5 This is a schematic diagram of the structure of the limit seat and the second drive assembly; Figure 6 This is a structural diagram of the lifting component and the second wheel assembly.

[0022] Explanation of reference numerals in the attached figures: 1. Base plate; 101. Flaw detection guide rail; 102. Movable base; 2. Operating table; 3. Seven-axis robot; 4. Limiting mechanism; 401. Limiting seat; 4011. First guide rail; 4012. Guide groove; 4013. Second guide rail; 402. First drive assembly; 4021. First drive rod; 4022. First drive disk; 4023. First slider; 4024. First slide block; 403. Second drive assembly; 4031. Second drive rod; 4032. Second drive disk; 4033. Second slider ; 4034, Second slide block; 404, First wheel set; 4041, Support base plate; 4042, First support wheel; 4043, First drive motor; 405, Lifting component; 4051, Lifting mounting seat; 4052, Lifting guide rail; 4053, Connecting plate; 4054, Lifting rod; 4055, Drive unit; 406, Second wheel set; 4061, Adjusting shaft; 4062, Mounting frame; 4063, Second support wheel; 5, Material support component; 501, Conveying rod; 502, Hinge joint; 503, Material support plate. Detailed Implementation

[0023] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] In the description of this application: unless otherwise stated, "a plurality of" means two or more. The terms "first," "second," "third," etc., in this application are intended to distinguish the objects referred to and do not have any special meaning in terms of technical connotation (e.g., they should not be construed as an emphasis on importance or order). Expressions such as "including," "comprising," and "having" also mean "not limited to" (certain units, components, materials, steps, etc.).

[0025] The terms used in this application, such as "upper," "lower," "left," "right," and "middle," are generally used to facilitate intuitive understanding by referring to the accompanying drawings, and are not absolute limitations on the positional relationships in the actual product. Changes in these relative positional relationships, without departing from the technical concept disclosed in this application, should also be considered within the scope of this application.

[0026] The following is combined Figures 1 to 6 The illustrated embodiments describe the technical solution of the present invention: This invention provides a collaborative control system for automatic flaw detection of end caps based on a seven-axis robot, as shown below. Figure 1-2As shown, it includes a base plate 1, an operating platform 2, and a seven-axis robot 3. The operating platform 2 is mounted on the base plate 1, and the seven-axis robot 3 is mounted on the base plate 1 and located on one side of the operating platform 2. It also includes at least three limiting mechanisms 4, which are evenly spaced and distributed along the circumference on the operating platform 2. The limiting mechanism 4 includes a limiting seat 401, a first drive assembly 402, a second drive assembly 403, a first wheel set 404, a lifting component 405, and a second wheel set 406. The limiting seat 401 has first guide rails 4011 symmetrically arranged on both sides of its top along its length. A guide groove 4012 is provided through the side wall below the first guide rails 4011. External plates are symmetrically arranged on both sides of the bottom of the limiting seat 401. A second guide rail 4013 is provided on the top surface of the external plates parallel to the first guide rails 4011. A first drive assembly 402 is located on the top of the limiting seat 401 between the two first guide rails 4011. A second drive assembly 403 is located on the bottom of the limiting seat 401 between the two guide grooves 4012. A first wheel set 404 is located at the drive end of the first drive assembly 402, and part of the first wheel set 404 is slidably connected to the first guide rails 4011. A lifting member 405 is located at the drive end of the second drive assembly 403 and is located on the side of the first wheel set 404 away from the center of the circular array of multiple limiting mechanisms 4. A second wheel set 406 is installed on the lifting end of the lifting member 405.

[0027] Specifically, multiple sets of circumferentially distributed limiting mechanisms 4 can form multi-point support and clamping for the end cap. The first drive component 402 and the second drive component 403 can respectively adjust the horizontal position of the first wheel group 404 and the second wheel group 406. The lifting component 405 can adjust the vertical height of the second wheel group 406. It can adapt to end caps of different diameters and different curvatures, realize the precise centering, stable clamping and rotation limiting of the end cap, ensure the smooth operation of the end cap during the flaw detection process, and avoid displacement deviation during the detection process.

[0028] During implementation, multiple sets of limiting mechanisms 4 are arranged in a circular array with the center of the operating table 2 as the center. The end cap to be tested is placed between the multiple sets of limiting mechanisms 4. The first drive component 402 drives the first wheel group 404 to move along the first guide rail 4011, adjusting the distance between the first wheel group 404 and the center. The second drive component 403 drives the lifting component 405 and the second wheel group 406 to move along the second guide rail 4013, adjusting the horizontal position of the second wheel group 406. The lifting component 405 adjusts the vertical height of the second wheel group 406, so that the first wheel group 404 and the second wheel group 406 are both in contact with the outer curved surface of the end cap. After the multiple sets of limiting mechanisms 4 are adjusted synchronously, the centering, clamping and limiting fixation of the end cap are completed.

[0029] In an exemplary embodiment, see Figure 1The base plate 1 is also provided with a flaw detection guide rail 101, which is set on the base plate 1 in a vertical direction perpendicular to the line connecting the seven-axis robot 3 and the operating table 2; the movable base 102 is slidably connected to the flaw detection guide rail 101; wherein, the seven-axis robot 3 is installed on the movable base 102, and a flaw detector is installed at the end of the seven-axis robot 3 away from the movable base 102.

[0030] Specifically, the flaw detection guide rail 101 and the movable base 102 can drive the seven-axis robot 3 to move in the horizontal direction, adjust the relative position of the seven-axis robot 3 with the operating table 2 and the end cap, adapt to the inspection requirements of end caps of different specifications, and at the same time, with the multi-degree-of-freedom motion of the seven-axis robot 3, the flaw detector can accurately follow the spatial trajectory of the end cap weld, improving the inspection coverage and accuracy.

[0031] During implementation, based on the specifications of the end cap to be inspected and the location of the weld, the host computer controls the moving base 102 to move along the flaw detection guide rail 101 to the preset station, driving the seven-axis robot 3 to the appropriate inspection position. During the flaw detection process, the seven-axis robot 3 drives the flaw detector to move synchronously with the spatial trajectory of the end cap weld, completing the full range inspection of the weld.

[0032] In an exemplary embodiment, see Figure 4 The first drive assembly 402 includes a first drive rod 4021, which is rotatably connected to the limiting seat 401 along a path parallel to the first guide rail 4011; a first drive disc 4022, which is coaxially connected to one end of the first drive rod 4021 near the lifting member 405; a first slider 4023, which is sleeved on the first drive rod 4021; a first slide block 4024, which is installed on the top of the first slider 4023 and slidably connected to the first guide rail 4011 on both sides of its bottom; and a first wheel set 404, which is disposed on the first slide block 4024.

[0033] Specifically, the first drive component 402 can drive the first wheel group 404 to make precise linear reciprocating motion along the first guide rail 4011, so as to achieve precise adjustment of the horizontal position of the first wheel group 404 and adapt to the clamping requirements of end caps of different diameters. At the same time, the first guide rail 4011 provides stable guiding support for the first slide block 4024, ensuring the stability and accuracy of the position adjustment of the first wheel group 404.

[0034] In practice, rotating the first drive disc 4022 drives the first drive rod 4021 to rotate. When the first drive rod 4021 rotates, it drives the first slider 4023 to move linearly along the axis of the first drive rod 4021. The first slider 4023 drives the first slide block 4024 to slide synchronously along the first guide rail 4011, thereby driving the first wheel set 404 to move, completing the adjustment of the horizontal position of the first wheel set 404. After the adjustment is completed, the position of the first drive rod 4021 is locked, realizing the positioning and fixing of the first wheel set 404.

[0035] In an exemplary embodiment, see Figure 5 The second drive assembly 403 includes a second drive rod 4031, which is rotatably connected to the limiting seat 401 along the length direction parallel to the guide groove 4012; a second drive disk 4032, which is coaxially connected to one end of the second drive rod 4031 near the first drive disk 4022; a second slider 4033, which is sleeved on the second drive rod 4031; a second slide block 4034, which is installed on the top of the second slider 4033 and whose two ends pass through the guide grooves 4012 on both sides and are slidably connected to the second guide rail 4013; and a lifting member 405 is installed on the part of the second slide block 4034 that extends out of the guide groove 4012.

[0036] Specifically, the second drive component 403 can drive the lifting component 405 and the second wheel set 406 to make precise linear reciprocating motion along the second guide rail 4013, so as to achieve precise adjustment of the horizontal position of the second wheel set 406, and cooperate with the first wheel set 404 to adapt to the support requirements of end caps with different curvatures. The guide groove 4012 and the second guide rail 4013 form a double guide to ensure the stability and accuracy of the movement of the second slide block 4034.

[0037] In practice, rotating the second drive disc 4032 drives the second drive rod 4031 to rotate. When the second drive rod 4031 rotates, it drives the second slider 4033 to move linearly along the axis of the second drive rod 4031. The second slider 4033 drives the second slide block 4034 to slide synchronously along the guide groove 4012 and the second guide rail 4013, thereby driving the lifting component 405 and the second wheel set 406 to move, completing the adjustment of the horizontal position of the second wheel set 406. After the adjustment is completed, the position of the second drive rod 4031 is locked, realizing the positioning and fixing of the horizontal position of the second wheel set 406.

[0038] In an exemplary embodiment, see Figure 6 The lifting component 405 includes a lifting mounting base 4051, which is mounted on a second slide block 4034. The lifting mounting base 4051 has symmetrical lifting slots on both sides, and a connecting plate 4053 is provided at the bottom of one of the lifting slots. Multiple lifting guide rails 4052 are symmetrically slidably connected to the lifting mounting base 4051. Two lifting guide rails 4052 on the same side are connected by a connecting block. The other side of the connecting base is slidably connected in the lifting slot. A lifting seat is connected to the top of the corresponding lifting guide rails 4052 on both sides. A second wheel set 406 is mounted on the lifting seat. A lifting rod 4054 passes through the connecting plate 4053 and is slidably connected to the connecting plate 4053. One end is connected to the lifting seat, and the other end extends freely downward. A drive unit 4055 is mounted on the connecting plate 4053 and provides lifting driving force for the lifting rod 4054.

[0039] Specifically, the lifting component 405 can drive the second wheel group 406 to make precise vertical lifting movements, realize the adjustment of the vertical height of the second wheel group 406, accurately match the curvature of the outer wall of the end cap, and form multi-point fit support with the first wheel group 404, further improving the stability of the end cap clamping. The lifting guide rail 4052 and the lifting groove provide guiding support to ensure the smoothness of the lifting process.

[0040] During implementation, the drive unit 4055 drives the lifting rod 4054 to move vertically up and down. The lifting rod 4054 drives the lifting seat to move up and down synchronously. The lifting seat slides smoothly vertically along the lifting groove of the lifting mounting seat 4051 via the lifting guide rail 4052, thereby driving the second wheel group 406 to complete the vertical height adjustment. After the adjustment is completed, the drive unit 4055 locks the position of the lifting rod 4054, realizing the positioning and fixation of the vertical height of the second wheel group 406.

[0041] In an exemplary embodiment, see Figure 4 The first slide block 4024 is inclined, and the first wheel assembly 404 is installed on the inclined surface of the first slide block 4024.

[0042] Specifically, the inclined first slide 4024 allows the support surface of the first wheel assembly 404 to form a suitable fitting angle with the arc-shaped outer wall of the end cap, thereby improving the fit between the first wheel assembly 404 and the outer wall of the end cap, increasing the contact friction, ensuring the stability of the end cap rotation drive, and preventing slippage.

[0043] During implementation, the inclined surface of the first slide block 4024 faces the center of the circular array of multiple sets of limiting mechanisms 4. After the first wheel group 404 is installed on the inclined surface, the wheel surface of the first support wheel 4042 can form a surface contact with the arc-shaped outer wall of the end cap, thereby improving the stability of support and drive.

[0044] In an exemplary embodiment, see Figure 4 The first wheel assembly 404 includes a bracket base plate 40411, which is disposed on the inclined surface of the first slide block 4024 and is parallel to the inclined surface; a support plate, which is rotatably connected to the higher end of the bracket base plate 40411; a first support wheel 4042, which is rotatably connected to the support plate, and the axial direction of the first support wheel 4042 forms an angle with the length direction of the first drive rod 4021; and a first drive motor 4043, which is coaxially connected to the first support wheel 4042 and mounted on the support plate.

[0045] Specifically, the rotatable support plate can adapt to the curvature of the outer wall of the end cap and automatically adjust the contact angle of the first support wheel 4042 to further improve the fit. The first drive motor 4043 can directly drive the first support wheel 4042 to rotate, thereby driving the end cap to rotate smoothly at a preset speed, providing stable rotational power for automated flaw detection, eliminating the need for additional rotating fixtures and simplifying the equipment structure.

[0046] During implementation, after the first support wheel 4042 is in contact with the outer wall of the head, the support plate can rotate adaptively with the curvature of the outer wall of the head. Adjust the angle of the first support wheel 4042 so that the first support wheel 4042 is completely in contact with the outer wall of the head. During the flaw detection process, the first drive motor 4043 starts and drives the first support wheel 4042 to rotate at a preset speed. Through friction, the head is driven to rotate synchronously and smoothly to cooperate with the flaw detection operation.

[0047] In an exemplary embodiment, see Figure 6 The second wheel assembly 406 includes an adjusting shaft 4061 that extends through the lifting seat along a length direction parallel to the second drive rod 4031; a mounting bracket 4062 located on the side of the adjusting shaft 4061 near the first wheel assembly 404; a second support wheel 4063 rotatably connected to the side of the mounting bracket 4062 near the first wheel assembly 404; and a buffer spring sleeved on the adjusting shaft 4061 and located between the mounting bracket 4062 and the lifting seat.

[0048] Specifically, the buffer spring enables the second support wheel 4063 to form an elastic support structure, which can adaptively compensate for the roundness error of the end cap and the slight jump during the rotation process, always maintaining close support with the outer wall of the end cap, further improving the stability of the end cap during rotation, avoiding vibration or displacement, and ensuring detection accuracy.

[0049] During implementation, after the second support wheel 4063 is in contact with the outer wall of the end cap, the buffer spring can adaptively compress or rebound according to the pressure of the outer wall of the end cap, causing the mounting bracket 4062 and the second support wheel 4063 to move slightly along the axial direction of the adjusting shaft 4061, compensating for the roundness error and rotational runout of the end cap, and always maintaining a tight fit between the second support wheel 4063 and the outer wall of the end cap, thus achieving stable auxiliary support.

[0050] In an exemplary embodiment, see Figure 3 It also includes a material support component 5, which includes a conveying rod 501; a hinge joint 502 located at one end of the conveying rod 501; and a material support plate 503 rotatably connected to the end of the hinge joint 502 away from the conveying rod 501.

[0051] Specifically, the material support 5 enables convenient loading and unloading of the end caps to be tested, reducing the labor intensity of manual operation. The rotatable material support plate 503 can adapt to the curved surface structure of the end cap, improving the stability of the end cap placement during the loading process and avoiding the risk of slippage.

[0052] During implementation, the end cap to be tested is placed on the support plate 503. The support plate 503 and the end cap are moved to the operating table 2 between the multiple limiting mechanisms 4 by the conveying rod 501. The support plate 503 can rotate adaptively through the hinge joint 502 to adapt to the curved surface of the end cap, so that the end cap is placed stably on the limiting mechanism 4, completing the loading operation. After the test is completed, the end cap is removed from the limiting mechanism 4 by the support piece 5, completing the unloading operation.

[0053] This application also provides a method for automatic flaw detection of end caps based on a seven-axis robot, which, based on the aforementioned collaborative control system for automatic flaw detection of end caps based on a seven-axis robot, includes the following steps: S1: The operator places the end cap to be tested onto the multiple limit mechanisms 4 on the operating table 2 via the material dragging component. The system detects and confirms that the end cap is placed stably in place. S2: According to the diameter specification of the end cap to be tested, the positions of the first wheel group 404 and the second wheel group 406 are adjusted by the first drive component 402, the second drive component 403 and the lifting component 405 to complete the centering clamping and rotation limit of the end cap; S3: Through the independent power supply and gateway wireless communication module of the rotating tooling, the device nodes are automatically refreshed within the local area network, and a two-way communication connection is established with the seven-axis robot 3, flaw detector, flaw detection reflector and host computer to build a closed-loop collaborative control system. S4: The host computer issues a flaw detection execution command, controls the mobile base 102 to move along the flaw detection guide rail 101 to the preset detection station, and the seven-axis robot 3 carries the flaw detector to the detection start position corresponding to the head weld, and simultaneously controls the flaw detection reflector to move to the corresponding detection position matched with the flaw detector. S5: Control the first support wheel 4042 of the first wheel group 404 to drive the end cap to rotate smoothly at a preset speed. At the same time, the seven-axis robot 3 drives the flaw detector to follow the spatial trajectory of the end cap weld in real time, collect the flaw detection data of the end cap weld in real time, and feed the collected data back to the host computer in real time. S6: The system collects the position information and operating status data of each execution unit in real time and feeds them back to the host computer. The execution master control program performs real-time calibration and anomaly control on the linkage timing and operating parameters of each unit. After the full circumference weld flaw detection of the head is completed, all execution units are reset to the initial position and the system waits for the next inspection cycle.

[0054] Specifically, this method achieves fully automated closed-loop operation of end cap loading, centering and clamping, system networking, flaw detection execution, data acquisition, and full-process control. It can realize precise coordination between end cap rotation and the three flaw detection actions of the seven-axis robot, greatly improving the automation level, detection accuracy and operation efficiency of end cap flaw detection, reducing the intensity of manual operation, and meeting the continuous flaw detection needs of large batches and multiple specifications of end caps.

[0055] During implementation, steps S1 to S6 are executed sequentially. After completing the full circumference weld flaw detection operation of a single head, all execution units are automatically reset and can directly enter the next inspection cycle, realizing continuous automated flaw detection of multiple heads. During the operation, the system collects the operating data of each unit in real time, calibrates the operating parameters in real time, and immediately stops the machine and issues an early warning when an abnormality occurs, ensuring the safety of equipment operation and the reliability of inspection results.

[0056] The technical features of the above embodiments can be combined in any way (as long as there is no contradiction in the combination of these technical features). For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described; these embodiments not explicitly written should also be considered to be within the scope of this specification.

[0057] The present application has been described in a relatively specific and detailed manner above through general descriptions and specific embodiments. It should be understood that, based on the technical concept of the present application, several conventional adjustments or further innovations can be made to these specific embodiments; however, as long as they do not depart from the technical concept of the present application, the technical solutions obtained by these conventional adjustments or further innovations also fall within the protection scope of the claims of the present application.

Claims

1. A head automatic flaw detection collaborative control system based on a seven-axis robot, comprising a bottom plate (1), an operation table (2) and a seven-axis robot (3), the operation table (2) is arranged on the bottom plate (1), the seven-axis robot (3) is arranged on the bottom plate (1) and located on one side of the operation table (2), characterized in that, It also includes at least three limiting mechanisms (4), evenly spaced and distributed circumferentially on the operating table (2), wherein the limiting mechanisms (4) include: The limiting seat (401) has a first guide rail (4011) symmetrically arranged on both sides of the top along the length direction, and a guide groove (4012) is provided through the side wall below the first guide rail (4011). The limiting seat (401) has an outer plate symmetrically arranged on both sides of the bottom, and a second guide rail (4013) is provided on the top surface of the outer plate parallel to the first guide rail (4011). The first drive assembly (402) is disposed on the top of the limiting seat (401) and located between the two first guide rails (4011); The second drive assembly (403) is located at the bottom of the limiting seat (401) and between the two guide grooves (4012); The first wheel set (404) is located at the drive end of the first drive assembly (402), and a portion of the first wheel set (404) is slidably connected to the first guide rail (4011). The lifting component (405) is located at the driving end of the second driving component (403) and is located on the side of the first wheel set (404) away from the center of the circumferential array of the plurality of limiting mechanisms (4). The second wheel assembly (406) is installed at the lifting end of the lifting component (405).

2. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 1, characterized in that, The base plate (1) is also provided with: The flaw detection guide rail (101) is set on the base plate (1) in a direction perpendicular to the line connecting the seven-axis robot (3) and the operating table (2); The movable base (102) is slidably connected to the flaw detection guide rail (101); The seven-axis robot (3) is mounted on the mobile base (102), and a flaw detector is installed at the end of the seven-axis robot (3) away from the mobile base (102).

3. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 1, characterized in that, The first driving component (402) includes: The first drive rod (4021) is rotatably connected to the limiting seat (401) along a path parallel to the first guide rail (4011); The first drive disc (4022) is coaxially connected to one end of the first drive rod (4021) near the lifting member (405); The first slider (4023) is sleeved on the first drive rod (4021); The first slide block (4024) is mounted on the top of the first slider (4023) and its bottom sides are slidably connected to the first guide rail (4011). The first wheel set (404) is disposed on the first slide block (4024).

4. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 3, characterized in that, The second drive component (403) includes: The second drive rod (4031) is rotatably connected to the limiting seat (401) along the length direction parallel to the guide groove (4012); The second drive disk (4032) is coaxially connected to the end of the second drive rod (4031) near the first drive disk (4022); The second slider (4033) is sleeved on the second drive rod (4031); The second slide block (4034) is installed on the top of the second slider (4033), and its two ends pass through the guide grooves (4012) on both sides and are slidably connected to the second guide rail (4013). The lifting member (405) is installed on the part of the second slide block (4034) that extends out of the guide grooves (4012).

5. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 4, characterized in that, The lifting component (405) includes: A lifting mounting base (4051) is installed on the second slide (4034). The lifting mounting base (4051) has symmetrical lifting grooves on both sides, and a connecting plate (4053) is provided at the bottom of one of the lifting grooves. Multiple lifting guide rails (4052) are symmetrically slidably connected to the lifting mounting base (4051). Two lifting guide rails (4052) located on the same side are connected by a connecting block. The other side of the connecting base is slidably connected in the lifting groove. The lifting seat is connected to the top of the corresponding lifting guide rail (4052) on both sides, and the second wheel set (406) is installed on the lifting seat; The lifting rod (4054) passes through the connecting plate (4053) and is slidably connected to the connecting plate (4053). One end is connected to the lifting seat, and the other end extends freely downward. The drive unit (4055) is mounted on the connecting plate (4053) and provides lifting drive force for the lifting rod (4054).

6. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 3, characterized in that, The first slide (4024) is inclined, and the first wheel set (404) is mounted on the inclined surface of the first slide (4024).

7. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 6, characterized in that, The first wheel set (404) includes: The bracket base plate (4041)(1) is set on the inclined surface of the first slide (4024) and is parallel to the inclined surface; The support plate is rotatably connected to the higher end of the bracket base plate (4041)(1); The first support wheel (4042) is rotatably connected to the support plate, and the axial direction of the first support wheel (4042) forms an angle with the length direction of the first drive rod (4021); The first drive motor (4043) is coaxially connected to the first support wheel (4042) and mounted on the support plate.

8. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 5, characterized in that, The second set of wheels (406) includes: An adjusting shaft (4061) is provided to pass through the lifting seat along a length direction parallel to the second drive rod (4031); Mounting bracket (4062) is provided on the side of the adjusting shaft (4061) near the first wheel set (404); The second support wheel (4063) is rotatably connected to the side of the mounting bracket (4062) near the first wheel assembly (404); A buffer spring is sleeved on the adjusting shaft (4061) and located between the mounting bracket (4062) and the lifting seat.

9. The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot according to claim 1, characterized in that, It also includes a material support component (5), which comprises: Conveyor rod (501); A hinge joint (502) is provided at one end of the conveying rod (501); The material support plate (503) is rotatably connected to the end of the hinge joint (502) away from the conveying rod (501).

10. A method for automatic flaw detection of end caps based on a seven-axis robot, characterized in that, The automatic flaw detection and collaborative control system for end caps based on a seven-axis robot, as described in any one of claims 1 to 9, comprises the following steps: S1: The operator places the end cap to be tested onto the multiple limit mechanisms (4) of the operating table (2) through the material dragging component. The system detects and confirms that the end cap is placed stably in place. S2: According to the diameter specification of the end cap to be tested, the positions of the first wheel group (404) and the second wheel group (406) are adjusted by the first drive assembly (402), the second drive assembly (403) and the lifting component (405) to complete the centering clamping and rotation limit of the end cap; S3: Through the independent power supply and gateway wireless communication module of the rotating tool, the device nodes are automatically refreshed within the local area network, and a two-way communication connection is established with the seven-axis robot (3), flaw detector, flaw detector reflector and host computer to build a closed-loop collaborative control system. S4: The host computer issues a flaw detection execution command, controls the mobile base (102) to move along the flaw detection guide rail (101) to the preset detection station, and the seven-axis robot (3) carries the flaw detector to the detection start position corresponding to the head weld, and simultaneously controls the flaw detection reflector to move to the corresponding detection position matched with the flaw detector. S5: Control the first support wheel (4042) of the first wheel group (404) to drive the end cap to rotate smoothly at the preset speed. At the same time, the seven-axis robot (3) drives the flaw detector to follow the spatial trajectory of the end cap weld synchronously and collect the flaw detection data of the end cap weld in real time, and feed the collected data back to the host computer in real time. S6: The system collects the position information and operating status data of each execution unit in real time and feeds them back to the host computer. The execution master control program performs real-time calibration and anomaly control on the linkage timing and operating parameters of each unit. After the full circumference weld flaw detection of the head is completed, all execution units are reset to the initial position and the system waits for the next inspection cycle.

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