A rubber layer defect detection device suitable for rubber roller

Abstract

The application provides a rubber layer defect detection equipment suitable for rubber roller, and belongs to the technical field of rubber roller detection and inspection, which comprises a water tank, an ultrasonic probe and a probe support, the water tank is internally provided with a supporting roller one and a supporting roller two, and the two groups of supporting rollers are provided with a first adjustable speed motor which drives the rotation of the supporting rollers; the water tank is filled with coupling liquid; the probe support is slidingly assembled on an axial slide rail, and the slide rail is provided with a second adjustable speed motor which drives the probe support to move along the axial direction of the rubber roller workpiece; a sliding block with locking function is vertically slidingly sleeved on a vertical column and can be locked and fixed, an oscillating arm is hinged to the lower end of the sliding block with locking function through a rotating shaft, and the ultrasonic probe is fixedly installed at one end of the oscillating arm away from the rotating shaft; the application effectively solves the problems of large consumption of coupling liquid, the non-self-adaptation of the probe pressing structure to rubber rollers with different diameters, the single scanning path, the high detection missing rate and the complicated operation of the existing rubber roller detection equipment by constructing an automatic spiral scanning system.

Description

Technical Field

[0001] This invention belongs to the field of rubber roller flaw detection and inspection technology, specifically a flaw detection device for rubber layer defects in rubber rollers. Background Technology

[0002] Rubber rollers play a crucial role in industries such as printing, papermaking, and material handling. Their structure consists of a metal roller core covered with a rubber layer. Hidden defects such as micro-bubbles, localized voids, or poor adhesion between the rubber layer and the roller core can easily occur within the rubber layer. These defects are difficult to identify visually or through conventional methods during manufacturing. Once the roller is in actual use, these defects gradually expand over time, causing surface cracking, rubber layer peeling, and consequently, distorted printed patterns, reduced material handling accuracy, and even the scrapping of entire batches of products, resulting in significant economic losses for manufacturing companies.

[0003] Currently, the industry lacks dedicated testing equipment for defects in the rubber layer of rubber rollers. Conventional ultrasonic testing devices generally employ a deep-water immersion design, requiring the rubber roller to be completely submerged in the coupling fluid. This results in high fluid consumption, high costs, and cumbersome subsequent cleaning and maintenance processes. The probe clamping mechanism of such devices is mostly a fixed structure, unable to flexibly adjust according to changes in the rubber roller diameter, leading to unstable contact between the probe and the rubber surface and susceptibility to signal interference. Furthermore, the scanning path is limited to linear or simple planar motion, making it difficult to completely cover the cylindrical surface of the rubber roller, creating blind spots and resulting in a high rate of missed detections. The operation involves complex manual intervention, leading to low testing efficiency and failing to meet the rapid and continuous batch inspection requirements of modern production lines. Summary of the Invention

[0004] The purpose of this application is to provide a flaw detection device for rubber layer defects suitable for rubber rollers, which solves the technical problems of high liquid consumption, unstable probe contact, blind spots in scanning, and low efficiency of conventional equipment.

[0005] The technical solution adopted by this invention to solve its technical problem is: a flaw detection device for rubber layer defects on rubber rollers, comprising a water tank, an ultrasonic probe, and a probe bracket; the water tank contains a first set of rollers and a second set of rollers, and the two sets of rollers are equipped with a first adjustable speed motor to drive their rotation; the water tank contains a coupling fluid; the probe bracket is slidably mounted on an axial slide rail, and the slide rail is equipped with a second adjustable speed motor to drive the probe bracket to move axially along the rubber roller workpiece; the probe bracket includes a vertical column, a slider with locking function, a rotating shaft, and a swing arm; the slider with locking function slides vertically... The movable sleeve is mounted on a vertical column and can be locked in place. The swing arm is hinged to the lower end of the slider with locking function via a rotating shaft. The ultrasonic probe is fixedly installed at the end of the swing arm away from the rotating shaft and is pressed against the surface of the rubber roller workpiece by the weight of the swing arm. Two sets of support rollers support the rotation of the rubber roller workpiece and move axially in coordination with the probe bracket, so that the ultrasonic probe can complete a spiral scan along the surface of the rubber roller workpiece. The ultrasonic probe is connected to an external flaw detection terminal, which can display the initial wave of the roller surface and the bottom wave of the roller core. Bubbles, voids, and adhesion defects inside the rubber layer will generate characteristic reflected waves between the initial wave and the bottom wave.

[0006] Furthermore, the water tank has a shallow liquid tank structure, and the height of the coupling liquid only covers the upper part of roller 1 and roller 2. The bottom of the rubber roller workpiece is immersed in the coupling liquid, and the upper part is exposed above the liquid surface.

[0007] Furthermore, the slider with locking function is equipped with locking bolts and locking wrenches. After the slider moves vertically up and down along the vertical column, it can be locked and positioned to accommodate rubber roller workpieces with different outer diameter specifications.

[0008] Furthermore, the swing arm is a gravity-fed type, and the weight of the swing arm itself provides a continuous downward clamping force for the ultrasonic probe, ensuring that the probe and the surface of the rubber roller workpiece are tightly fitted without gaps.

[0009] Furthermore, the first and second adjustable speed motors can be independently adjusted to match the spiral scanning spacing requirements of rubber rollers of different lengths and diameters.

[0010] Furthermore, the axial slide rail is arranged parallel to the axes of roller one and roller two, and the length of the slide rail is greater than the maximum axial length of the rubber roller workpiece.

[0011] Furthermore, the ultrasonic probe is a water-immersion ultrasonic probe, which is electrically connected to the flaw detection terminal. The flaw detection terminal acquires, stores, and displays ultrasonic waveform data in real time.

[0012] Furthermore, the axes of idler roller one and idler roller two are arranged parallel and at the same height, the distance between the two idler rollers is adapted to the outer diameter of the roller core of the rubber roller workpiece, and the outer circle of the idler roller is wrapped with an anti-slip rubber layer.

[0013] The beneficial effects of this invention are as follows: By constructing an automated spiral scanning system, the problems of high coupling fluid consumption, inability of the probe clamping structure to adapt to rubber rollers of different diameters, high false negative rate due to a single scanning path, and cumbersome operation in existing rubber roller flaw detection equipment are effectively solved. This equipment can achieve efficient and accurate detection of internal defects in the rubber layer of rubber roller workpieces, significantly improving the quality control level of rubber roller products and reducing the risk of batch product scrapping due to hidden defects. Attached Figure Description

[0014] The invention will now be further described with reference to the accompanying drawings.

[0015] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the probe bracket of the present invention; Figure 3 This is a schematic diagram of the workpiece scanning path of the present invention.

[0016] In the diagram: 1. Idler roller one; 2. Idler roller two; 3. Workpiece; 4. Water tank; 5. Coupling fluid; 6. Ultrasonic probe; 7. Probe bracket; 8. Slide rail; 9. Swing arm; 10. Rotary shaft; 11. Slider with locking function; 12. Vertical column. Detailed Implementation

[0017] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0018] Please see Figures 1-3 As shown, this embodiment of the invention provides a rubber layer defect detection device suitable for rubber rollers, including a water tank 4, an ultrasonic probe 6, and a probe bracket 7. The water tank 4 contains a first roller 1 and a second roller 2, which are driven to rotate by a first adjustable-speed motor. The probe bracket 7 is slidably mounted on an axial slide rail 8 and is driven to move axially along the rubber roller workpiece 3 by a second adjustable-speed motor. The probe bracket 7 includes a vertical column 12, a slider 11 with a locking function, a rotating shaft 10, and a swing arm 9. The ultrasonic probe 6 is fixedly installed at the end of the swing arm 9 away from the rotating shaft, relying on the weight of the swing arm to press against the surface of the rubber roller workpiece 3 to be inspected. The two sets of rollers support the rotation of the rubber roller workpiece 3, and in conjunction with the axial movement of the probe bracket, the ultrasonic probe 6 completes a spiral scan along the surface of the rubber roller workpiece, thereby achieving effective detection of internal defects in the rubber layer.

[0019] This application effectively solves the problems of high coupling fluid consumption, inability of probe clamping structure to adapt to rubber rollers of different diameters, high false negative rate due to single scanning path, and cumbersome operation in existing rubber roller flaw detection equipment by constructing an automated spiral scanning system. This equipment can achieve efficient and accurate detection of internal defects in the three rubber layers of rubber roller workpieces, significantly improving the quality control level of rubber roller products and reducing the risk of batch product scrapping due to hidden defects.

[0020] In some of the embodiments described above in this application, ultrasonic testing using a water tank filled with coupling fluid is proposed. However, in practical applications, if the water tank adopts a conventional large-area deep-water immersion structure, it will result in a huge amount of coupling fluid being used, which not only increases the operating cost of the equipment, but also makes the overall structure of the water tank bulky, which is not conducive to the maintenance and cleaning of the equipment. Moreover, the deep-water immersion method is a waste of resources for rubber rollers that only require surface adhesive layer inspection and increases the complexity of workpieces entering and leaving the tank.

[0021] In response, this application further proposes a flaw detection device for rubber layer defects of rubber rollers, wherein the water tank 4 is a shallow liquid tank structure, the height of the coupling liquid 5 only covers the upper part of the idler roller 1 and the idler roller 2, the bottom of the rubber roller workpiece 3 is immersed in the coupling liquid and the upper part is exposed above the liquid surface.

[0022] Specifically, the water tank 4 is designed as a shallow liquid tank structure with relatively small depth and volume, aiming to limit the total volume of the coupling fluid 5 contained therein, rather than completely immersing the rubber roller workpiece 3 to be tested. This structural design can significantly reduce the amount of coupling fluid 5 used, thereby reducing the operating cost of the equipment and simplifying the equipment structure, facilitating subsequent maintenance and cleaning. For example, the depth of the water tank 4 can be precisely controlled so that it can only hold a small amount of coupling fluid 5, or the bottom of the water tank 4 can be designed as an arc or V-shaped structure that matches the lower contour of idler roller 1 and idler roller 2, to further minimize the filling space of the coupling fluid 5.

[0023] Meanwhile, the level of the coupling fluid 5 is precisely controlled so that it only submerges the upper parts of idler roller 1 and idler roller 2. This precise fluid level control is key to achieving localized immersion flaw detection. Its function is to ensure that the rubber roller workpiece 3 can fully contact the coupling fluid 5 during rotation, while avoiding unnecessary deep immersion, thereby conserving the coupling fluid 5. The fluid level can be controlled in various ways. For example, a level sensor can be used in conjunction with an automatic fluid replenishment or drainage system, such as a float valve, ultrasonic level gauge, or pressure sensor, to monitor and adjust the fluid level in real time. In addition, an overflow port can be provided on the side wall of the water tank 4. When the coupling fluid 5 reaches the preset height, excess liquid is discharged through the overflow port, thereby maintaining a stable fluid level.

[0024] In this configuration, when the rubber roller workpiece 3 is supported and rotated by roller 1 and roller 2, its bottom is immersed in the coupling liquid 5, while its upper part remains exposed above the liquid surface. This immersion method is the core application effect of the shallow liquid tank structure, which ensures acoustic coupling between the ultrasonic probe 6 and the rubber roller workpiece 3, while minimizing the consumption of the coupling liquid 5. Through the rotation of the rubber roller workpiece 3, its entire surface can pass through the coupling liquid 5 area in sequence, achieving full-surface detection. This state is a direct result of the aforementioned shallow liquid tank structure and liquid level control. By utilizing the rotational movement of the rubber roller workpiece 3, the probe 6 can always perform ultrasonic coupling through the surface of the rubber roller workpiece 3 immersed in the coupling liquid 5 during scanning.

[0025] Through the above technical solution, this application designs the water tank 4 as a shallow liquid tank structure and precisely controls the liquid level of the coupling liquid 5 so that it only submerges the upper parts of the first roller 1 and the second roller 2. With this configuration, when the rubber roller workpiece 3 is supported and rotated by the first roller 1 and the second roller 2, its bottom can be immersed in the coupling liquid 5, while its upper part is exposed above the liquid surface. This partially submerged coupling method significantly reduces the total amount of coupling liquid 5 filled and consumed, effectively reducing the operating cost and maintenance burden of the equipment. Specifically, since the entire surface of the rubber roller workpiece 3 passes through the area of ​​the coupling liquid 5 sequentially during rotation, the ultrasonic probe 6 can always obtain good acoustic coupling through the surface of the rubber roller workpiece 3 immersed in the coupling liquid 5 when performing a spiral scan along the surface of the rubber roller workpiece 3, ensuring the effectiveness of flaw detection. At the same time, compared with the traditional deep-water immersion structure, the shallow liquid tank design makes the overall structure of the water tank 4 lighter, facilitating the movement, maintenance, and cleaning of the equipment. Furthermore, immersing only the bottom of the rubber roller workpiece 3 in the coupling fluid 5 simplifies the workpiece loading and unloading process, improves inspection efficiency, and is particularly suitable for batch factory inspection needs, avoiding the resource waste and operational complexity caused by deep water immersion. This design, while ensuring the quality of flaw detection, achieves precise control over the amount of coupling fluid used, improving the economy and practicality of the equipment.

[0026] In some of the embodiments described above in this application, a slider with a locking function is proposed to support the ultrasonic probe. However, in the actual testing process, due to the large difference in the outer diameter of rubber roller workpieces of different specifications, if the height of the probe bracket cannot be flexibly adjusted and reliably fixed, the probe will not always be kept in the optimal testing position, thereby affecting the testing accuracy or causing poor contact between the probe and the roller surface.

[0027] In this regard, this application further proposes that the slider 11 with locking function is equipped with locking bolts and locking wrenches. After the slider is vertically raised and lowered along the vertical column 12, it can be locked and positioned to adapt to rubber roller workpieces 3 with different outer diameter specifications.

[0028] Specifically, the locking slider 11 is a mechanical component capable of linear movement along a specific guide rail (i.e., the vertical column 12). Its "locking function" means it has the ability to be fixed in place after moving to a predetermined position. The slider 11 can be designed with an internal threaded hole, allowing locking through an external bolt screwed into and pressed against the vertical column 12; alternatively, the slider 11 may have a clamping mechanism on its side, clamping the vertical column 12 via a lever or eccentric wheel mechanism; or, the slider 11 and the vertical column 12 may employ a friction plate or wedge structure, achieving locking through external pressure.

[0029] The locking bolt is a standard mechanical part used to provide fastening force. Its function is to generate axial force through thread engagement, thereby fixing the slider 11 at a specific height of the vertical column 12. The locking bolt can be an internal hex bolt with an internal hexagonal hole at the head, requiring an internal hex wrench for tightening to provide a larger locking torque; alternatively, a wing bolt or hand-tightening bolt can be used, with a head designed for easy hand operation, allowing for initial tightening without tools and convenient quick adjustment; or, a bolt with a washer can be used, increasing the contact area and improving the reliability and stability of the locking. The locking wrench is a tool used to apply torque to tighten or loosen the locking bolt. The locking wrench can be an internal hex wrench for operating internal hexagonal bolts, providing precise torque control; it can also be an open-end wrench or box wrench for operating external hexagonal bolts, suitable for applications requiring greater operating space or torque; or it can be a torque wrench, capable of setting and displaying the applied torque value to ensure the tightening force meets design requirements and avoids over-tightening or under-tightening.

[0030] The vertical movement of the slider along the vertical column 12 refers to the ability of the slider 11 with locking function to move up and down along the axis of the vertical column 12 to adjust the relative height of the ultrasonic probe 6. The slider 11 and the vertical column 12 can be connected by a precision sliding guide rail, allowing for smooth vertical movement through manual pushing and pulling or auxiliary mechanisms (such as a counterweight). Alternatively, the slider 11 can have an integrated screw and nut mechanism, with a screw fixed on the vertical column 12. Rotating the screw handwheel or driving motor allows for precise and controllable vertical movement of the slider 11. Furthermore, the slider 11 and the vertical column 12 can be connected by a rack and pinion transmission, with the driving gear rolling along a rack fixed to the column to achieve the movement of the slider 11.

[0031] The lockable positioning refers to the ability of the slider 11 to be reliably fixed at any preset height on the vertical column 12 after completing the vertical lifting adjustment, preventing accidental displacement during equipment operation or external interference. This can be achieved by using locking bolts and locking wrenches, where the end of the locking bolt acts directly or through a pressure block on the surface of the vertical column 12 to generate sufficient friction for self-locking; alternatively, a series of equally spaced positioning holes are preset on the vertical column 12, and the slider 11 is equipped with a retractable positioning pin. When the slider 11 moves to a specified height, the positioning pin inserts into the positioning hole to achieve mechanical positioning, further aided by locking bolts for auxiliary tightening; or, an eccentric wheel or lever clamping mechanism is used, where the eccentric wheel or lever generates clamping force on the vertical column 12 through the operating handle, thereby achieving rapid locking.

[0032] Through the above technical solution, this application effectively solves the compatibility problem of rubber roller workpieces 3 with different outer diameters by setting a locking bolt and a locking wrench on the slider 11 with a locking function, and enabling it to be vertically raised and lowered along the vertical column 12 for locking and positioning. Specifically, when it is necessary to inspect rubber roller workpieces 3 with different diameters, the operator can manually operate the slider 11 to vertically raise and lower along the vertical column 12 according to the actual outer diameter of the rubber roller workpiece 3, adjusting the ultrasonic probe 6 to a height that is compatible with the surface of the rubber roller workpiece 3. Once adjusted, the locking bolt can be tightened with the locking wrench to firmly lock the slider 11 in the current position. This design ensures that the ultrasonic probe 6 maintains close and stable contact with the surface of the rubber roller workpiece 3 throughout the entire spiral scanning process, avoiding poor coupling or detection blind spots caused by improper probe height, thereby significantly improving the accuracy and reliability of flaw detection. At the same time, this solution simplifies the equipment debugging process for rubber rollers of different specifications, improves the ease of operation, and enables the equipment to be widely used for batch inspection needs of rubber rollers of various specifications.

[0033] In some embodiments described above, a probe holder is used to drive an ultrasonic probe for helical scanning to detect defects in rubber rollers. However, in actual testing, if there is a gap between the probe and the surface of the rubber roller or the contact pressure is unstable, it can lead to poor ultrasonic coupling, resulting in signal attenuation or artifacts, thus affecting the detection accuracy. Simply relying on manual adjustment or rigid fixation makes it difficult to ensure that the probe remains in close contact with the surface of the rubber roller with different curvatures throughout the scanning process, thereby limiting the reliability of the flaw detection.

[0034] In this regard, this application further proposes that the swing arm 9 is a gravity counterweight type swing arm, and the weight of the swing arm itself provides a continuous downward pressing force for the ultrasonic probe 6, ensuring that the probe and the surface of the rubber roller workpiece 3 are tightly fitted without gaps.

[0035] Specifically, a gravity-assisted counterweight swing arm refers to a swing arm that utilizes its own weight or an additional counterweight to generate a continuous force under gravity, thereby achieving compression or balance on a target object. This design avoids complex mechanical or pneumatic pressurization mechanisms, resulting in a simple and reliable structure. For example, the structural design and material selection of the swing arm 9 can give it sufficient self-weight, which can be directly used as a clamping force. This can be achieved by using a high-density material to manufacture the swing arm 9, or by optimizing the geometry of the swing arm 9 so that its center of gravity is located outside the rotating shaft 10, thus generating a continuous downward torque. Alternatively, a counterweight can be placed on the swing arm 9, and the clamping force applied by the swing arm 9 to the ultrasonic probe 6 can be precisely controlled by adjusting the mass and position of the counterweight. For example, an adjustable counterweight can be placed at the end of the swing arm 9 away from the rotating shaft 10 or above it to adapt to different detection requirements or probe weights.

[0036] The weight of the swing arm itself provides a continuous downward clamping force for the ultrasonic probe 6. This means that the swing arm 9, through its own gravity, continuously presses the ultrasonic probe 6 against the surface of the rubber roller workpiece 3 to be tested. This clamping force is constant and stable, unaffected by fluctuations in external power or air supply. For example, the swing arm 9 is hinged to the lower end of the slider 11 with a locking function via a pivot 10, and the ultrasonic probe 6 is fixedly mounted on the end of the swing arm 9 away from the pivot 10. When the swing arm 9 hangs naturally under gravity, its weight acts on the ultrasonic probe 6 through a lever principle, causing it to generate a continuous vertical clamping force on the surface of the rubber roller workpiece 3. Alternatively, the center of gravity of the swing arm 9 is designed below the pivot 10, so that the swing arm 9 always tends to rotate downwards, thereby stably pressing the ultrasonic probe 6 against the surface of the rubber roller workpiece 3. This design ensures that even if there is slight radial runout or irregularity on the surface of the rubber roller workpiece 3, the probe 6 can adaptively adjust through the slight swing of the swing arm 9 to maintain close contact.

[0037] Ensuring a tight, gapless fit between the probe and the surface of the rubber roller workpiece 3 is crucial to guaranteeing the absence of air gaps between the ultrasonic probe 6 and the surface of the rubber roller workpiece 3, thereby achieving effective coupling and transmission of the ultrasonic signal. Air gaps cause total reflection of ultrasonic waves at the interface, severely attenuating the signal and affecting the flaw detection effect. For example, the continuous downward pressing force provided by the swing arm 9 can overcome any minor unevenness or surface tension of the coupling fluid 5 on the surface of the rubber roller workpiece 3, ensuring a stable coupling fluid layer is formed between the detection surface of the probe 6 and the surface of the rubber roller workpiece 3, thus achieving effective transmission of sound waves. Alternatively, the adaptive nature of the gravity-fed swing arm 9 allows the probe 6 to dynamically adjust its contact state with the surface of the rubber roller workpiece 3 during rotation and axial movement. Even if there are minor deviations in the diameter of the rubber roller workpiece 3 or slight radial runout on its surface, the swing arm 9 can compensate for these changes through its free swing, always maintaining a tight fit between the probe 6 and the surface of the rubber roller workpiece 3, avoiding the formation of gaps.

[0038] By introducing a gravity-fed counterweight swing arm 9, this application effectively solves the problems of unstable contact and poor coupling between the ultrasonic probe 6 and the surface of the rubber roller workpiece 3, leading to signal attenuation and decreased detection accuracy. The swing arm 9 utilizes its own weight to provide a continuous and stable downward clamping force to the ultrasonic probe 6, ensuring that the probe 6 remains tightly fitted to the surface of the rubber roller workpiece 3, eliminating any potential air gaps between the probe and the rubber roller. This design not only simplifies the complexity of traditional pressure mechanisms and reduces maintenance costs, but more importantly, it ensures that the clamping force can dynamically compensate for minor undulations or radial runouts on the surface of the rubber roller workpiece 3 during the rotation of the rubber roller workpiece 3 and the movement of the ultrasonic probe 6 along the axial slide rail 8 for helical scanning. Therefore, the transmission stability and consistency of the ultrasonic signal are significantly improved, effectively avoiding signal attenuation or artifacts caused by poor contact, thereby greatly improving the detection accuracy and reliability of defects such as air bubbles, voids, and adhesive defects within the adhesive layer.

[0039] In some of the solutions mentioned above in this application, a flaw detection method of spiral scanning by rotating the roller and moving the probe axially is proposed. However, in practical applications, there are significant differences in length and diameter of rubber rollers of different specifications. If the motion parameters of the drive mechanism are fixed, the density of the scanning path cannot be flexibly adjusted. This makes it difficult to balance detection efficiency and coverage integrity when dealing with rubber rollers of different sizes, and problems such as missed detection or excessively long detection time are likely to occur.

[0040] In this regard, this application further proposes that the first adjustable speed motor and the second adjustable speed motor can be independently adjusted to match the spiral scanning spacing requirements of rubber rollers of different lengths and diameters.

[0041] Through the above technical solution, this application provides an effective solution to the significant differences in length and diameter of different specifications of rubber rollers, and the resulting challenges in adjusting the scanning path. Specifically, by independently adjusting the rotational speed of roller 1 and roller 2 using a first adjustable-speed motor, the circumferential linear speed of the workpiece 3 to be inspected can be precisely adjusted according to its diameter, thereby ensuring that the circumferential range covered by the ultrasonic probe 6 per unit time meets the expected detection accuracy requirements. Simultaneously, by independently adjusting the axial movement speed of the probe support 7 using a second adjustable-speed motor, the pitch of the spiral scan can be flexibly controlled according to the length of the workpiece 3 and the preset scanning density. This independent speed control configuration of the first and second adjustable-speed motors allows the equipment to dynamically match the optimal spiral scanning spacing according to the geometric characteristics of different specifications of rubber roller workpieces 3. Therefore, this solution not only ensures the ultrasonic probe 6's requirement for full coverage of the rubber layer, effectively avoiding missed detections, but also avoids the problems of low detection efficiency and excessively long detection time caused by an overly dense scanning path, thus achieving a balance between detection accuracy and operational efficiency, significantly improving the applicability and detection performance of the equipment.

[0042] In some of the embodiments described above in this application, a scheme is proposed to perform spiral scanning by supporting the rubber roller workpiece 3 with roller 1 and roller 2 and moving axially in conjunction with the probe bracket 7. However, in practical applications, if the arrangement of the axial slide rail 8 and the support structure of the roller lack spatial geometric constraints, the probe 6 may not be able to cover the entire effective length of the rubber roller workpiece 3 during the movement, or problems such as probe collision and stroke limitation may occur at the end of the scanning stroke, thereby affecting the integrity of the detection.

[0043] In this regard, this application further proposes that the axial slide rail 8 is arranged parallel to the axis of idler roller 1 and idler roller 2, and the length of the slide rail is greater than the maximum axial length of the rubber roller workpiece 3.

[0044] Specifically, the axial slide rail 8 is arranged parallel to the axes of idler roller 1 and idler roller 2, aiming to ensure that the trajectory of the ultrasonic probe 6 remains strictly parallel to the rotation axis of the rubber roller workpiece 3 as it moves axially along the rubber roller workpiece 3. This parallel arrangement is the basis for achieving stable and uniform scanning. It ensures that the relative positional relationship between the probe 6 and the surface of the rubber roller workpiece 3 remains consistent throughout the entire axial stroke, avoiding probe tilting or distance changes caused by angular deviations, thereby ensuring the stability of ultrasonic signal coupling and the accuracy of detection results. In actual operation, this parallelism can be ensured through high-precision machining and assembly processes. For example, during equipment manufacturing and assembly, precision measuring tools (such as laser alignment instruments or optical collimators) are used to precisely align the mounting reference surface of the axial slide rail 8 with the axes of idler roller 1 and idler roller 2. Alternatively, a slide rail mounting base with a fine-tuning mechanism can be used, allowing for fine adjustment of the parallelism of the axial slide rail 8 during equipment commissioning to compensate for manufacturing tolerances or installation errors, thereby achieving the required parallelism.

[0045] Meanwhile, the slide rail length is greater than the maximum axial length of the rubber roller workpiece 3 to ensure that the travel of the probe bracket 7 on the axial slide rail 8 can completely cover the entire axial range of the longest specification rubber roller workpiece 3 that can be detected. This means that the probe 6 can not only scan the main body of the rubber roller workpiece 3, but also extend to both ends, thereby achieving blind-angle detection of rubber layer defects on the rubber roller workpiece 3. The slide rail length can be determined based on the axial length of the largest specification rubber roller workpiece 3 that can be compatible with the equipment design, and a certain safety margin can be reserved on this basis, such as adding 5% to 10% extra stroke, to ensure that the probe 6 can completely move out of the effective detection area of ​​the rubber roller workpiece 3, facilitating loading, unloading or end inspection. Alternatively, the slide rail length can be designed as a modular or telescopic structure, by adding or reducing slide rail sections to adapt to the maximum axial length of the rubber roller workpiece 3 for different batches or different customer needs, thereby optimizing equipment size and cost while ensuring detection coverage.

[0046] By employing the aforementioned technical solution, the axial slide rail 8 is arranged parallel to the axes of roller 1 and roller 2, ensuring that the ultrasonic probe 6 maintains a constant geometric relationship with the surface of the rubber roller workpiece 3 during axial movement. This avoids changes in the distance between the probe and the surface of the rubber roller workpiece 3 caused by slide rail tilting or non-parallelism, thus guaranteeing the stability of ultrasonic signal acquisition. Simultaneously, by setting the slide rail length to be greater than the maximum axial length of the rubber roller workpiece 3, the limitation on the scanning stroke is eliminated in physical space, allowing the probe 6 to move smoothly from one end of the rubber roller workpiece 3 to the other, ensuring complete coverage of the entire rubber layer surface. This effectively solves the problem of missed detection due to insufficient stroke, providing a reliable mechanical motion basis for achieving full-coverage spiral scanning and significantly improving the integrity and reliability of rubber layer defect detection.

[0047] In some of the solutions mentioned above in this application, ultrasonic probes are proposed for detecting internal defects in rubber rollers. However, in actual flaw detection operations, how to achieve real-time acquisition, storage and visualization of flaw detection data, and how to ensure the stability and accuracy of signal transmission between the probe and the flaw detection terminal are the key to realizing automated and standardized testing of rubber rollers. If there is a lack of effective signal processing and data interaction mechanisms, the test results will not be effectively recorded and analyzed, making it difficult to meet the quality traceability requirements of batch factory testing.

[0048] In this regard, this application further proposes that the ultrasonic probe 6 is a water immersion ultrasonic probe, which is electrically connected to the flaw detection terminal signal, and the flaw detection terminal collects, stores and displays ultrasonic waveform data in real time.

[0049] Specifically, the ultrasonic probe 6 is designed as a water-immersion ultrasonic probe. A water-immersion ultrasonic probe is a probe specifically designed for ultrasonic testing in a liquid medium. Its core feature is that it uses water or other coupling liquid 5 as the acoustic coupling medium to effectively eliminate the air gap between the probe and the surface of the rubber roller workpiece 3, significantly reducing acoustic impedance mismatch. This ensures that ultrasonic energy is efficiently transmitted from the probe to the interior of the workpiece and that the signal reflected back from the interior of the workpiece is received. For example, the probe itself can be waterproof-encapsulated, and its internal components such as the crystal and acoustic lens can operate stably in a liquid environment. Furthermore, its acoustic beam characteristics (such as focus, frequency, and bandwidth) are optimized to adapt to propagation in a water medium. Alternatively, the probe can be integrated into a small water tank or water spray device, forming a coupling with the surface of the rubber roller workpiece 3 through a water column or water film, ensuring effective transmission of the ultrasonic signal.

[0050] Simultaneously, the ultrasonic probe 6 is electrically connected to the flaw detection terminal. This electrical connection refers to the establishment of a data communication link between the ultrasonic probe 6 and the flaw detection terminal via cable or radio signal transmission. This is fundamental to achieving real-time and accurate transmission of ultrasonic signals from the probe to the terminal. For example, a coaxial cable can be used for connection, as it has good anti-interference capabilities and can effectively transmit high-frequency ultrasonic signals, ensuring signal integrity and fidelity. Alternatively, a multi-core shielded cable can be used, which includes signal lines, power lines, and grounding wires to provide stable power supply and reliable signal transmission while reducing external electromagnetic interference.

[0051] Based on this, the flaw detection terminal can acquire, store, and display ultrasonic waveform data in real time. As the control and data processing center of the entire detection system, the core function of the flaw detection terminal is to process the received ultrasonic signals in real time. Real-time acquisition means that the terminal can continuously receive and digitize the analog signals transmitted by the probe, converting them into a digital data stream that can be processed by a computer. Storage function refers to saving the acquired waveform data, along with related detection parameters, timestamps, and other information, to internal or external storage devices for subsequent data analysis, report generation, and quality traceability. Display function refers to presenting the ultrasonic waveform intuitively to the operator through a graphical user interface (GUI) in the form of A-scan, B-scan, or C-scan, allowing them to observe waveform characteristics in real time and determine whether defects exist. For example, a flaw detection terminal can be equipped with a high-speed analog-to-digital converter (ADC) and a digital signal processor (DSP), along with dedicated software algorithms, to achieve rapid acquisition, processing, and waveform reconstruction of ultrasonic signals, and display them in real time on a high-resolution display screen; or, the flaw detection terminal can adopt a modular design, receive signals through a data acquisition card, perform data processing and storage management by the main control unit, and visualize the waveforms through an external display or integrated display module, while also providing a data export interface.

[0052] Through the above technical solution, the ultrasonic probe 6 is designed as a water-immersion ultrasonic probe and electrically connected to the flaw detection terminal. The flaw detection terminal can acquire, store, and display ultrasonic waveform data in real time, thus constructing an efficient and reliable closed-loop system for processing adhesive layer defect detection data. The water-immersion ultrasonic probe 6 utilizes the coupling fluid 5 as the acoustic coupling medium, effectively overcoming the acoustic impedance difference between the probe and the surface of the rubber roller workpiece 3, ensuring that the ultrasonic signal can penetrate the adhesive layer with high efficiency and accurately capture the characteristic reflected waves generated by internal defects (such as bubbles, voids, and adhesion defects). The electrical connection between the probe 6 and the flaw detection terminal ensures the real-time and stable transmission of the detection signal, enabling the flaw detection terminal to instantly receive and process the raw waveform data acquired by the probe 6. The real-time acquisition, storage, and display functions of the flaw detection terminal not only solve the problems of data traceability and auditability during the detection process, but also provide operators with direct evidence for judging internal defects in the adhesive layer through intuitive waveform visualization. This data processing mechanism transforms physical inspection results into standardized digital waveform data, significantly improving the automation, objectivity, and reliability of rubber roller defect detection, and meeting the needs of batch factory inspection for quality traceability and efficiency.

[0053] In some of the embodiments described above in this application, ultrasonic probes are proposed for detecting internal defects in rubber rollers. However, in actual flaw detection operations, due to the lack of a mechanism for real-time acquisition, storage, and display of ultrasonic signals, the waveform data during the detection process cannot be effectively recorded and traced. This makes it difficult for operators to accurately interpret and subsequently analyze hidden defects such as tiny bubbles and voids inside the rubber layer, thereby affecting the reliability and traceability of the detection results.

[0054] In this regard, this application further proposes that the ultrasonic probe 6 is a water immersion ultrasonic probe, which is electrically connected to the flaw detection terminal signal, and the flaw detection terminal collects, stores and displays ultrasonic waveform data in real time.

[0055] Specifically, the ultrasonic probe 6 is designed as a water-immersed ultrasonic probe. A water-immersed ultrasonic probe is an ultrasonic sensor specifically designed to operate in a liquid coupling medium. It typically has good waterproof sealing properties and can stably transmit and receive ultrasonic signals in the coupling liquid 5 within the water tank 4. For example, the probe can use a piezoelectric ceramic wafer as the core transducer element, externally encapsulated in corrosion-resistant and waterproof materials such as stainless steel or special plastics, and equipped with an acoustic lens to focus the ultrasonic beam; alternatively, the probe integrates a pre-amplification circuit to enhance weak ultrasonic echo signals, reduce attenuation and noise interference during transmission, and ensure signal quality. This water-immersed ultrasonic probe 6 can efficiently and stably couple ultrasonic waves into the interior of the rubber roller workpiece 3 through the coupling liquid 5, reducing acoustic energy loss, improving detection sensitivity and signal-to-noise ratio, thereby more accurately detecting minute defects inside the rubber layer.

[0056] The ultrasonic probe 6 is electrically connected to the flaw detection terminal. This electrical connection means that the ultrasonic probe 6 transmits the received ultrasonic signals to the flaw detection terminal via cable or wireless transmission, while the flaw detection terminal can also send excitation signals to the probe, thereby establishing a data path between the probe and the terminal. This allows the raw ultrasonic signals acquired by the probe to be received, processed, and analyzed by the flaw detection terminal. For example, a coaxial cable connection can be used to ensure low-loss transmission of high-frequency ultrasonic signals and provide good anti-interference capabilities; alternatively, fiber optic transmission or wireless transmission modules can be used to provide stronger anti-electromagnetic interference capabilities or greater operational flexibility in specific application scenarios.

[0057] The flaw detection terminal can acquire ultrasonic wave data in real time. Real-time acquisition means that the flaw detection terminal can synchronously and continuously acquire the echo signal received by the ultrasonic probe 6 and convert it into a digital data stream, ensuring that the echo information of every ultrasonic pulse during the detection process can be captured in a timely manner. For example, the flaw detection terminal has a built-in high-speed analog-to-digital converter (ADC) to digitize the analog ultrasonic signal at a preset sampling frequency and resolution, and the signal is then preliminarily processed by a digital signal processor (DSP); or, the flaw detection terminal uses a hardware acceleration module based on an FPGA (Field Programmable Gate Array) to realize parallel high-speed acquisition and preprocessing of ultrasonic signals to meet real-time requirements.

[0058] The flaw detection terminal can also store ultrasonic waveform data. Storage function refers to the terminal's ability to save the real-time acquired digitized ultrasonic waveform data to its internal or external storage medium for later review, analysis, and traceability. For example, the flaw detection terminal can be equipped with a large-capacity solid-state drive (SSD) or hard disk drive (HDD) to store raw waveform data, detection parameters, timestamps, and detection results; alternatively, the terminal can upload data to a cloud server or local database via a network interface for centralized data management and remote access.

[0059] Furthermore, the flaw detection terminal can display ultrasonic wave data. The display function refers to the terminal's ability to present ultrasonic wave data graphically, such as an A-scan waveform, through its display screen, allowing operators to visually observe the propagation and reflection of ultrasonic waves within the rubber roller workpiece 3. For example, the flaw detection terminal may use a high-resolution LCD screen to draw ultrasonic wave diagrams in real time via a graphical user interface (GUI), providing interactive functions such as zooming and panning; alternatively, the terminal may support multi-screen display, simultaneously displaying A-scan, B-scan, or C-scan images to provide more comprehensive defect information.

[0060] Through the above technical solution, a water-immersion ultrasonic probe 6 is introduced and an electrical signal connection is established between it and the flaw detection terminal. The flaw detection terminal can acquire, store, and display ultrasonic waveform data in real time. Specifically, the water-immersion ultrasonic probe 6 operates in the coupling fluid 5, ensuring that ultrasonic waves can be efficiently and stably coupled into the interior of the rubber roller workpiece 3, improving the sensitivity of defect detection. The flaw detection terminal, through its real-time acquisition function, can continuously acquire the initial wave, bottom wave, and defect feature reflection wave generated when ultrasonic waves propagate within the rubber layer, ensuring the integrity and timeliness of the detection data. Simultaneously, the flaw detection terminal stores this waveform data, providing reliable raw data support for subsequent quality assessment, defect analysis, and process improvement, effectively solving the problem of untraceable detection results. Furthermore, by displaying waveform data in real time on the terminal, operators can intuitively observe the dynamic changes of the waveform, instantly identifying hidden defects such as tiny bubbles, voids, and bonding defects within the rubber layer, greatly improving the transparency and accuracy of the detection process. This closed-loop data processing configuration not only improves testing efficiency and reliability, but also ensures the rigor and traceability of the rubber roller factory inspection, thereby effectively avoiding the scrapping of batch products due to hidden defects.

[0061] The following example will provide a more detailed explanation of the above technical solution: In a rubber roller manufacturing plant, various rubber roller workpieces produced in batches need to undergo quality inspection before leaving the factory to ensure that there are no hidden defects such as air bubbles, voids, or adhesion defects inside the rubber layer. Traditional inspection methods have problems such as high consumption of coupling fluid, inability to adapt to rubber rollers of different diameters, and incomplete scanning coverage, resulting in low inspection efficiency and high missed detection rate.

[0062] To address the aforementioned issues, the factory introduced a rubber layer defect detection device. When a rubber roller workpiece 3 to be inspected is placed inside the water tank 4 of the device, it is supported by idler rollers 1 and 2. These two sets of idler rollers are arranged with parallel axes and equal heights, and the spacing is adapted to the outer diameter of the roller core of the workpiece 3. The anti-slip rubber layer covering their outer circumference ensures the stability of the workpiece 3 during rotation. The water tank 4 contains coupling fluid 5, and its level is precisely controlled, only submerging the upper parts of idler rollers 1 and 2, so that the bottom of the workpiece 3 is immersed in the coupling fluid 5, while the upper part is exposed above the surface. This shallow water tank structure significantly reduces the consumption of coupling fluid 5, and compared with the traditional large-area deep water immersion structure, it has obvious economic and environmental advantages.

[0063] At the start of the test, the first adjustable-speed motor drives roller 1 and roller 2 to rotate synchronously, causing the rubber roller workpiece 3 to rotate at a set speed. Simultaneously, the ultrasonic probe 6 moves axially via the probe bracket 7. The probe bracket 7 is slidably mounted on an axial slide rail 8, which is arranged parallel to the axes of roller 1 and roller 2. Its length is greater than the maximum axial length of the rubber roller workpiece 3, ensuring coverage of the entire axial range of the workpiece 3. The second adjustable-speed motor drives the probe bracket 7 to move along the axial slide rail 8. Both the first and second adjustable-speed motors can be independently adjusted, allowing the equipment to flexibly adjust the spacing of the spiral scan according to the different lengths and diameters of the rubber roller workpiece 3. This achieves a comprehensive and thorough scan of the adhesive layer on the surface of the rubber roller workpiece 3, overcoming the problem of existing technologies having a single scanning path and being unable to completely cover the adhesive layer.

[0064] On the probe holder 7, the vertical column 12 provides a vertical sliding channel for the slider 11 with locking function. When it is necessary to inspect rubber roller workpieces 3 with different outer diameters, the operator adjusts the position of the slider 11 with locking function on the vertical column 12 by tightening the locking bolt and locking wrench, so as to adjust its position and lock it in place, thereby adapting to rubber roller workpieces 3 with different diameters. The swing arm 9 is hinged to the lower end of the slider 11 with locking function via the rotating shaft 10, and the ultrasonic probe 6 is fixedly installed at the end of the swing arm 9 away from the rotating shaft 10. The swing arm 9 adopts a gravity counterweight design, and its own weight provides a continuous downward pressing force for the ultrasonic probe 6, ensuring that the ultrasonic probe 6 and the surface of the rubber roller workpiece 3 are always in close contact without any gaps, ensuring the effectiveness of ultrasonic coupling and avoiding signal attenuation or loss due to poor contact.

[0065] The ultrasonic probe 6, an immersion ultrasonic probe, emits ultrasonic waves into the interior of the rubber roller workpiece 3 with the assistance of the coupling fluid 5 and receives the reflected waves. The probe 6 is electrically connected to the flaw detection terminal via a signal line. The flaw detection terminal collects, stores, and displays the ultrasonic wave data in real time. The initial wave on the roller surface and the bottom wave of the roller core can be clearly seen on the terminal display interface. If defects such as bubbles, voids, or adhesion defects exist inside the rubber layer, these defects will generate characteristic reflected waves between the initial wave and the bottom wave. Operators can accurately determine the location and nature of the defects by analyzing these characteristic reflected waves. This detection method can effectively identify hidden defects that are not visible to the naked eye, preventing defects from gradually expanding during the use of the rubber roller and leading to product scrap.

[0066] Through the aforementioned collaborative operation, the equipment achieves efficient, accurate, and comprehensive detection of defects in the three layers of various rubber roller workpieces, significantly improving detection efficiency and quality, and meeting the needs of batch factory inspection of rubber rollers.

[0067] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A flaw detection device for rubber layer defects suitable for rubber rollers, characterized in that: The device includes a water tank (4), an ultrasonic probe (6), and a probe bracket (7). The water tank (4) contains a first roller (1) and a second roller (2), both sets of which are equipped with a first adjustable-speed motor to drive their rotation. The water tank (4) contains a coupling fluid (5). The probe bracket (7) is slidably mounted on an axial slide rail (8), which is equipped with a second adjustable-speed motor to drive the probe bracket to move axially along the rubber roller workpiece. The probe bracket (7) includes a vertical column (12), a slider (11) with locking function, a rotating shaft (10), and a swing arm (9). The slider (11) with locking function slides vertically. The swing arm (9) is mounted on the vertical column (12) and can be locked and fixed. The swing arm (9) is hinged to the lower end of the slider (11) with locking function through the rotating shaft (10). The ultrasonic probe (6) is fixedly installed at the end of the swing arm (9) away from the rotating shaft. It is pressed against the surface of the rubber roller workpiece (3) to be tested by the weight of the swing arm. The two sets of support rollers support the rotation of the rubber roller workpiece (3) and move axially with the probe bracket so that the ultrasonic probe (6) completes a spiral scan along the surface of the rubber roller workpiece. The ultrasonic probe is connected to an external flaw detection terminal. The terminal can display the initial wave of the roller surface and the bottom wave of the roller core. The bubbles, voids, and bonding defects inside the rubber layer will generate characteristic reflected waves between the initial wave and the bottom wave.

2. The rubber layer defect detection equipment for rubber rollers according to claim 1, characterized in that: The water tank (4) is a shallow liquid tank structure. The height of the coupling liquid (5) only covers the upper part of roller 1 (1) and roller 2 (2). The bottom of the rubber roller workpiece (3) is immersed in the coupling liquid and the upper part is exposed above the liquid surface.

3. The rubber layer defect detection equipment for rubber rollers according to claim 1, characterized in that: The slider (11) with locking function is equipped with locking bolts and locking wrenches. After the slider is vertically raised and lowered along the vertical column (12), it can be locked and positioned to adapt to rubber roller workpieces (3) with different outer diameter specifications.

4. The rubber layer defect detection equipment for rubber rollers according to claim 1, characterized in that: The swing arm (9) is a gravity counterweight swing arm. The weight of the swing arm itself provides a continuous downward pressing force to the ultrasonic probe (6), ensuring that the probe and the surface of the rubber roller workpiece are tightly fitted without gaps.

5. A flaw detection device for rubber layer defects suitable for rubber rollers according to claim 1, characterized in that: The first and second adjustable speed motors can be independently adjusted to match the spiral scanning spacing requirements of rubber rollers of different lengths and diameters.

6. The rubber layer defect detection equipment for rubber rollers according to claim 1, characterized in that: The axial slide rail (8) is arranged parallel to the axis of roller 1 (1) and roller 2 (2), and the length of the slide rail is greater than the maximum axial length of the rubber roller workpiece (3).

7. The rubber layer defect detection equipment for rubber rollers according to claim 1, characterized in that: The ultrasonic probe (6) is a water immersion ultrasonic probe, which is electrically connected to the flaw detection terminal. The flaw detection terminal collects, stores, and displays ultrasonic data in real time.

8. A flaw detection device for rubber layer defects suitable for rubber rollers according to claim 1, characterized in that: The axes of roller 1 (1) and roller 2 (2) are arranged parallel and at the same height. The distance between the two rollers is adapted to the outer diameter of the roller core of the rubber roller workpiece (3). The outer circle of the roller is wrapped with an anti-slip rubber layer.

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