A pin-magnetic ring automatic detection and assembly method, integrated device and detection device

Abstract

The application discloses a bolt-magnetic ring automatic detection and assembling method, an integrated device and a detection device, and belongs to the technical field of steel structure bolt resistance welding. The detection device comprises a base, a bolt detection unit and a magnetic ring detection unit. The size of a bolt bead is detected through a point laser detection at the end of a guide rail. A lifting and rotating mechanism is adopted to cooperate with a line laser sensor to realize scanning of defects around the magnetic ring. The integrated device integrates the above detection device, a transfer and assembling mechanism and an assembling lifting mechanism. Double independent clamps are adopted to clamp the bolt and the magnetic ring respectively, so that the unqualified workpieces are independently thrown and fed, and assembling is completed through synchronous bolt pressing and magnetic ring lifting. The detection structure has high universality, can be adapted to various material distribution mechanisms, reduces the waste rate from the source through front-end quality inspection, effectively improves the assembling efficiency and assembling precision through independent throwing and synchronous assembling, and is suitable for the automatic production of steel structure bolt welding processes such as nuclear power containment.

Description

Technical Field

[0001] This invention relates to the technical field of an automatic assembly device and method for stud-magnetic ring in the resistance welding process of studs in steel structures. Background Technology

[0002] Shear studs and their matching protective magnetic rings are core components of the bolted welding process in steel structures. They are widely used in the shear connection construction of steel structures such as nuclear power plant containment vessels and large stadiums. Before welding each shear stud, a ceramic magnetic ring must be pre-installed to concentrate the electric arc, protect the molten pool, and form the weld. Ultra-large curved steel plate structures with complex curvature variations require a dense array of shear studs, placing extremely high demands on assembly efficiency and precision.

[0003] Currently, the assembly of studs and magnetic rings is still mainly done manually, with operators needing to insert each stud into the magnetic ring and transfer it to the welding station one by one. This method is not only labor-intensive and inefficient, but also difficult to adapt to the characteristics of projects with tight construction schedules and huge component sizes. Existing automated equipment is mainly designed for flat steel plates or small components. For ultra-large curved steel plates with diameters of tens of meters and complex curvature variations, there is a lack of effective spatial adaptability solutions, making it difficult to achieve continuous automated operation of dense array stud placement.

[0004] Furthermore, the precise assembly of the studs and magnetic rings involves multi-degree-of-freedom coordinated control, including multiple processes such as material separation, transfer, inspection, and insertion, with motion accuracy required to be controlled at the millimeter level. Existing equipment has simple control logic and poor independence of the actions of each mechanism, making it difficult to achieve high-precision synchronous coordination; moreover, there is a common problem of defective components such as incomplete molten stud beads and broken or damaged magnetic rings flowing into the welding process, causing scrap and even posing engineering safety hazards.

[0005] In the prior art, patent CN202422381797 discloses a fully automatic assembly tooling for stud welding and ceramic rings, and patent CN110238576 discloses an automatic welding robot with T-shaped studs and ceramic rings. Neither of these patents mentions the solution to the risk of finished product defects in the assembly process.

[0006] Therefore, there is an urgent need for an assembly and installation device that can automatically and accurately assemble studs and magnetic rings and has defect detection capabilities to meet the process requirements of large-size automated welding production lines. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide an automatic detection mechanism for studs and magnetic rings, an automatic detection and assembly method for studs and magnetic rings, and an integrated device.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An automatic detection device for studs and magnetic rings includes: a base, a stud detection unit and a magnetic ring detection unit mounted on the base, and a control module. The stud detection unit includes a stud discharge guide rail and a molten bead detection assembly. The stud discharge guide rail extends along the feeding direction to receive continuously arranged studs, and its discharge end has a detection opening at the bottom. The molten bead detection assembly is located below the stud discharge guide rail and is used to detect the size and state of the molten beads at the stud end of the stud at the end of the stud guide rail online. The magnetic ring detection unit includes a lifting and rotating mechanism and a magnetic ring defect detection group. The lifting and rotating mechanism is located below the discharge end of the magnetic ring discharge guide rail, used to receive the magnetic ring and lift it upwards, while simultaneously driving the magnetic ring to rotate uniformly around its own axis; the magnetic ring defect detection component is located above and beside the discharge end of the magnetic ring discharge guide rail, used to collect the entire circumferential contour of the rotating magnetic ring online and identify defects; the control module is electrically connected to the molten bead detection component, the magnetic ring defect detection component, and the lifting and rotating mechanism, used to determine whether the workpiece is qualified based on the detection data, and output a trigger signal for throwing unqualified workpieces.

[0009] Furthermore, the stud detection unit also includes a stud lateral distribution assembly and a portal frame; the portal frame is fixed to the base, and its crossbeam spans the discharge end of the stud discharge guide rail; the lateral distribution assembly is located on the crossbeam of the portal frame and can move laterally perpendicular to the feeding direction to laterally separate a single stud at the foremost end of the stud discharge guide rail to the receiving station. Even further, the stud lateral distribution assembly includes a lateral drive component and a slot, the slot's opening being adapted to the shape of the stud head; the lateral drive component is inverted and fixed below the crossbeam of the portal frame, and its output end is connected to the slot.

[0010] Furthermore, the stud discharge guide rail is a U-shaped cross-section guide rail, with an internal cavity to accommodate the stud rod and the stud head exposed on the top surface of the guide rail.

[0011] Furthermore, the molten bead detection component is a point laser rangefinder or a spring strain gauge pressure detection component; if a point laser rangefinder is used, the laser emitting end is vertically upward, directly facing the detection opening of the discharge guide rail.

[0012] Furthermore, the magnetic ring detection unit also includes a magnetic ring discharge guide rail, which is a torsion U-shaped guide rail used to convert the vertically arranged magnetic rings upstream into a horizontal posture and transport them to the discharge end.

[0013] Furthermore, the magnetic ring detection unit also includes a magnetic ring dispensing component and a limiting device. The magnetic ring dispensing component is located on the side of the discharge end of the magnetic ring discharge guide rail, and includes a horizontal drive component and a pusher component connected to the output end of the horizontal drive component. It is used to laterally separate the single magnetic ring at the front end of the guide rail to the lifting position (such as directly above the lifting and rotating mechanism). The limiting device is located at the end of the pushing path of the magnetic ring dispensing component and is used to limit the initial lifting position of the magnetic ring.

[0014] Furthermore, the lifting and rotating mechanism includes a vertical drive component and a rotary drive component. The rotary drive component is fixed to the output end of the vertical drive component and rises and falls synchronously with the vertical drive component. The output end of the rotary drive component is provided with a positioning head that is adapted to the inner hole of the magnetic ring.

[0015] Furthermore, the magnetic ring defect detection component is a line laser profile sensor or a structured light camera; the line laser profile sensor or structured light camera is fixed on the base, and its detection end is horizontally aligned with the outer circumferential surface of the lifted magnetic ring to collect the outer circumferential profile data of the entire magnetic ring.

[0016] An integrated automatic detection and assembly device for studs and magnetic rings includes a frame, an automatic stud-magnetic ring detection device, a transfer and assembly mechanism, an assembly lifting mechanism, and a control unit. The automatic stud-magnetic ring detection device is located at the feed end of the frame. The transfer and assembly mechanism is horizontally reciprocatingly mounted on the frame. The assembly lifting mechanism is located on the frame and directly below the assembly station, and is used to lift the magnetic ring upwards to facilitate stud insertion. The transfer assembly mechanism includes independently controlled pin clamping components and magnetic ring clamping components, which are used to clamp the tested pins and magnetic rings respectively and transfer them to the assembly station. The control unit is electrically connected to the stud-magnetic ring automatic detection device, the transfer assembly mechanism, and the assembly lifting mechanism, respectively. It is used to control the independent throwing process of unqualified workpieces according to the detection results, and to control the pressing action of the stud clamping assembly and the lifting action of the assembly lifting mechanism to be executed synchronously.

[0017] Furthermore, the frame is provided with a linear guide rail extending in the horizontal direction and a horizontal drive module. The transfer assembly mechanism also includes a movable bracket, which is connected to the linear guide rail via a slider. The horizontal drive module is used to drive the movable bracket to reciprocate along the linear guide rail. The stud clamping assembly and the magnetic ring clamping assembly are arranged side by side on the movable bracket. The stud clamping assembly has a vertical feed degree of freedom, and the magnetic ring clamping assembly has a horizontal extension degree of freedom.

[0018] Furthermore, the control unit is used to: when the stud detection fails, control the stud clamping assembly to move the failed stud to the throwing position for release, and return to the waiting position for re-retrieving; when the magnetic ring detection fails, control the magnetic ring clamping assembly to move the failed magnetic ring to the throwing position for release, and return to the waiting position for re-retrieving; when a single workpiece fails, the clamping state of the other workpiece remains unchanged.

[0019] An automatic detection and assembly method for studs and magnetic rings includes the following steps: S1 piece-by-piece material separation: Separates the continuously conveyed studs and magnetic rings one by one laterally and positions them to the corresponding inspection station; S2 Online Inspection: The dimensions of the molten beads at the end of the stud are inspected to determine if the beads are qualified; the magnetic ring is driven to rotate uniformly around its own axis, and the outer circumference contour data of the entire magnetic ring is collected to determine whether the magnetic ring is qualified; S3 Material Picking and Independent Disposal: Two independently controlled clamps pick up studs and magnetic rings respectively; if a single workpiece is determined to be unqualified, the corresponding clamp is controlled to carry the unqualified workpiece to the disposal position for disposal, and then returns to the waiting position to pick up a qualified workpiece again, while the other qualified workpiece remains in the clamping state. S4 Synchronous Assembly: Two sets of fixtures carry qualified studs and magnetic rings to the assembly station and are aligned coaxially. The studs are fed downward and the magnetic rings are lifted upward in a synchronous manner to complete the insertion and assembly of the studs and magnetic rings. S5 Discharge Transfer: The magnetic ring clamp loosens and retracts horizontally to avoid the impact, allowing the downstream material handling mechanism to remove the assembled stud-magnetic ring assembly as a whole.

[0020] Furthermore, in step S2 above, the detection of defects on the outer periphery of the magnetic ring is specifically as follows: a line laser profile sensor or a structured light camera is used to align with the outer periphery of the magnetic ring, and profile data is continuously collected during the uniform rotation of the magnetic ring. The data is unfolded into a two-dimensional profile curve, and the abrupt change characteristics of the curve are identified to determine whether there are any breakage or gap defects.

[0021] Furthermore, in step S3 above, the detection and ejection processes of the stud and the magnetic ring are independent of each other; when both workpieces are unqualified, the corresponding ejection and replenishment actions are executed in sequence.

[0022] Furthermore, in step S4 above, the downward stroke of the stud and the upward stroke of the magnetic ring are matched at speed through position closed-loop control, and the relative speed between the two remains constant during the insertion process.

[0023] The beneficial effects of this invention are: 1. The detection structure is highly targeted and widely adaptable. The core detection structure only needs to be matched with the end of the discharge guide rail, and can be adapted to various conventional material distribution and feeding mechanisms in existing technologies. It does not require large-scale modification of the upstream production line, and has low modification cost and strong versatility. The solution that combines bottom laser detection of the stud, magnetic ring lifting and rotation and line laser full-circumference scanning has no blind spots and can achieve millimeter-level accuracy, effectively reducing the missed detection rate.

[0024] 2. Pre-shipment quality inspection reduces the risk of defective products at the source. Defect detection of workpieces is completed at the end of the material discharge process, and unqualified products are rejected in advance to prevent defective products from flowing into the subsequent welding process, effectively reducing the welding scrap rate and eliminating potential quality and safety hazards in the project. In addition, the detection and feeding are carried out simultaneously without taking up additional assembly time.

[0025] 3. Independent clamping and independent throwing improve work efficiency. The studs and magnetic rings are held by two independently controlled clamping mechanisms, and the detection and ejection processes are independent of each other. When a single workpiece is unqualified, only the corresponding replenishment process is executed, without the need for overall reset and re-removal, which greatly reduces invalid actions and improves assembly efficiency.

[0026] 4. Dual-axis synchronous assembly, high assembly precision. The assembly process employs dual-axis synchronous control of stud pressing and magnetic ring lifting, ensuring uniform force during insertion and preventing workpiece damage from impacts. The coaxiality of the assembly is stable and controllable, effectively guaranteeing the quality of subsequent welding and meeting high-precision assembly requirements.

[0027] 5. Modular design, easy to integrate The testing device can be used as an independent functional module or integrated into an automated assembly line to adapt to different production scenarios. The overall structure of the equipment is compact and can be directly connected to the upstream vibratory feeder and the downstream robotic arm welding, making it easy to integrate into existing automated production lines.

[0028] The following describes specific embodiments of the present invention with reference to the accompanying drawings: Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of the integrated automatic detection and assembly device for studs and magnetic rings provided in an embodiment of the present invention.

[0030] Figure 2 This is a schematic diagram of the automatic detection device for studs and magnetic rings in an embodiment of the present invention.

[0031] Figure 3 This is a cross-sectional structural diagram of the stud detection unit in an embodiment of the present invention.

[0032] Figure 4 This is a schematic diagram of the magnetic ring detection unit in an embodiment of the present invention.

[0033] Figure 5 This is a schematic diagram illustrating the cooperation between the transfer assembly mechanism and the assembly lifting mechanism in an embodiment of the present invention.

[0034] Figure 6 This is a schematic diagram of the detection and assembly process flow according to an embodiment of the present invention, wherein... Figure 6-1 Figure 6-6 shows the status of each process step in sequence; Figure 7 This is a schematic diagram showing the unfolded profile of the damaged magnetic ring obtained by line laser scanning in an embodiment of the present invention.

[0035] Figure label: 100 bases 200 stud detection units 201 Stud discharge guide rail, 202 Molten bead detection assembly, 203 Stud transverse distribution assembly, 204 Portal bracket, 205 First position detection component 300 magnetic ring detection unit 301 Lifting and rotating mechanism; 302 Magnetic ring defect detection component; 303 Magnetic ring discharge guide rail; 304 Magnetic ring dispensing component; 305 Limiting component; 306 Second position detection component. 400 rack, 401 linear guide, 402 horizontal drive module 500 transfer assembly mechanism 501 Bolt clamping assembly, 502 Magnetic ring clamping assembly, 503 Movable bracket 600 sets of lifting mechanisms 700 studs 800 magnetic ring Detailed Implementation

[0036] The specific embodiments described herein are merely illustrative of the technical solutions of this patent and are not intended to limit the scope of the disclosed technical solutions. It should also be noted that, for ease of description, the accompanying drawings show only the parts relevant to the technical solutions of this disclosure, and not the entire structure.

[0037] Before discussing the exemplary embodiments in more detail, it should be mentioned that the structure of the device components and / or modules mentioned in the embodiments, unless otherwise described in detail, is something that can be understood by those skilled in the art based on existing public technologies or is a commercially available product.

[0038] like Figure 1As shown, the integrated automatic detection and assembly device for studs and magnetic rings provided in this embodiment mainly includes a frame 400, an automatic detection device for studs and magnetic rings, a transfer and assembly mechanism 500, and a control unit. The frame 400 is fixed to the ground or equipment platform with bolts, serving as the installation reference for the entire machine. The detection device is bolted to the feed end side plate of the frame 400 through multiple sets of trapezoidal diagonal braces, connecting to the upstream stud vibratory feeder and magnetic ring vibratory feeder to complete online defect detection and piece-by-piece separation of materials. The transfer and assembly mechanism 500 is horizontally movable on the frame 400, responsible for material picking, throwing, and assembly operations. The control unit adopts a PLC control system, which is electrically connected to each power component and detection component, coordinating the timing and logic control of the entire machine's actions.

[0039] I. Automatic Detection Device for Studs and Magnetic Rings like Figure 2 As shown, the testing device uses base 100 as its mounting foundation and integrates a stud testing unit 200, a magnetic ring testing unit 300, and a pneumatic valve island assembly. The pneumatic valve island assembly serves as the solenoid valve manifold for all pneumatic components of the testing device, uniformly controlling the timing of each cylinder's operation. The testing device can be used as an independent functional module to connect to downstream assembly equipment, or it can be integrated into an integrated assembly device.

[0040] 1. Stud Detection Unit 200 like Figure 3 As shown, the stud detection unit 200 takes the end detection structure as its core and is equipped with a material distribution structure to realize the integration of detection and material distribution. Specifically, it includes a stud discharge guide rail 201, a molten bead detection component 202, a stud transverse material distribution component 203, a portal bracket 204, and a first position detection component 205.

[0041] Core detection structure: The stud discharge guide 201 is a U-shaped metal guide rail that extends along the feeding direction. Its internal cavity accommodates the shank portion of the stud 700, with the stud head exposed on the top surface of the guide rail. An inspection opening is provided at the bottom of the discharge end of the guide rail, exposing the molten bead 701 of the lower half of the stud. The discharge guide rail specifications can be selected as 59×19×5mm.

[0042] The molten bead detection component 202 employs a point laser rangefinder sensor, fixed to the base 100, located directly below the discharge end of the stud discharge guide rail 201. The laser emitter points vertically upwards, directly facing the detection opening at the bottom of the guide rail. As the stud is conveyed along the guide rail to the end, the point laser rangefinder sensor measures the distance to the molten bead 701 at the bottom of the stud in real time. If the measured value exceeds a preset threshold, it is determined that the molten bead is missing or improperly installed, and the signal is uploaded to the control module. This detection structure only requires modification to the end of the guide rail by making an opening, and can be adapted to various upstream material distribution and feeding structures. As an alternative, the molten bead detection component 202 can also be replaced with a spring strain gauge pressure detection component, which detects the size and integrity of the molten bead by the distribution change of the pressure value.

[0043] Matching material distribution and positioning structure: The portal frame 204 spans the discharge end of the stud discharge guide 201 and consists of two uprights with adjusting bolt holes and a horizontal beam, fixed to the base 100. Multiple bolt holes are provided along the height of the uprights to adjust the installation height of the horizontal beam to accommodate studs of different lengths. The top of each upright is bent at 90° and the horizontal beam is fixed with bolts. For reference: the portal frame is 215mm high and 250mm wide, assembled from 5mm thick metal sheet through sheet metal processing, and has 6 adjusting holes with a hole spacing of 15mm.

[0044] The stud transverse feeding assembly 203 includes a transverse drive component and a slot. The transverse drive component is a drive cylinder, which is inverted and fixed below the center of the crossbeam of the portal frame 204. The output end is connected to the slot via bolts. When the drive cylinder is in the initial position, the slot opening is directly opposite the stud discharge guide rail 201, and the slot opening cross-section is consistent with the shape of the stud head. The extrusion force of subsequent studs pushes the head of the foremost stud into the slot. Then the cylinder is activated, causing the slot to shift laterally by 38mm, misaligning the individual stud to the waiting position and separating it from the subsequently arranged studs.

[0045] Preferably, a first position detection component 205 is further provided, which adopts a through-beam laser sensor and is installed on the upper half of the two columns of the portal frame 204. The through-beam direction passes through the slot of the workstation to be picked up, which is used to obtain the accurate positioning of the slot, ensuring that the clamped position of the stud is on the same vertical plane as the downstream fixture, thus ensuring the clamping accuracy.

[0046] 2. Magnetic ring detection unit 300 like Figure 4 As shown, the magnetic ring detection unit 300 takes the lifting and rotating detection structure as its core and is equipped with a material pushing and distributing structure to realize the integration of detection and distributing. Specifically, it includes a lifting and rotating mechanism 301, a magnetic ring defect detection component 302, a magnetic ring discharge guide rail 303, a magnetic ring distributing component 304, a limiting component 305, an installation platform, and a second position detection component 306.

[0047] The mounting platform serves as the mounting reference for the magnetic ring detection unit and is assembled from three right-angled triangular bracing steel plates and one horizontal rectangular steel plate. Threaded holes are formed on the two right-angled sides of each of the three triangular bracing steel plates, connecting to the base structure of base 100 and the horizontal rectangular steel plate respectively, forming a stable cantilevered support structure. For reference: triangular bracing dimensions are 160×65×5mm, and the horizontal rectangular steel plate dimensions are 460×96×8mm.

[0048] Core detection structure: The lifting and rotating mechanism 301 is located below the discharge end of the magnetic ring discharge guide rail 303, and includes a vertical drive component and a rotating drive component. The vertical drive component can be a drive cylinder, installed below the mounting platform; the rotating drive component can be a servo motor, fixed to the output end of the vertical drive component, and rises and falls synchronously with the cylinder; a positioning head is provided at the end of the rotating shaft of the servo motor, which can be inserted into the inner hole of the magnetic ring for positioning and receiving. When the magnetic ring is conveyed to the lifting position, the vertical drive component drives the servo motor to lift upward, raising the magnetic ring 800 to the detection height; then the servo motor starts, driving the magnetic ring 800 to rotate uniformly around its own axis. As an alternative, the rotating drive component can also be a stepper motor or a uniform speed rotating cylinder.

[0049] The magnetic ring defect detection component 302 employs a line laser profile sensor, mounted on the installation platform beside the end of the magnetic ring's discharge section, with the detection end horizontally aligned with the outer circumference of the lifted magnetic ring. During the magnetic ring's rotation, the line laser sensor continuously acquires its side profile data, unfolding the entire circumference into a two-dimensional profile curve. By identifying abrupt changes and depressions in the curve, it determines whether the magnetic ring has defects such as breakage or gaps. If the defect is deemed unacceptable, the signal is uploaded to the control module. Alternatively, the line laser profile sensor can be replaced with a structured light camera to acquire richer three-dimensional profile information and improve detection accuracy.

[0050] Matching material distribution and positioning structure: The magnetic ring discharge guide rail 303 is a torsion-type U-shaped metal guide rail, consisting of a torsion cover plate and a U-shaped metal profile with a torsion cross-section, with a series of magnetic rings loaded in the internal cavity. Its function is to gradually convert the vertically arranged magnetic rings output from the upstream magnetic ring vibratory feeder into a horizontal posture through the torsion of the rail, and transport them to the discharge end, facilitating the pushing of the magnetic ring distribution assembly, and completing the peripheral defect detection in the horizontal state.

[0051] The magnetic ring feeding assembly 304 includes a horizontal drive component and a pusher component. The horizontal drive component, which is a horizontal drive cylinder, is fixed on the mounting platform and located to the side of the magnetic ring discharge guide rail 303. Its output end is connected to the pusher component. When the magnetic ring is conveyed to the discharge end, the horizontal drive cylinder pushes the pusher component to move laterally, pushing the first magnetic ring to the lifting position at the limiting component 305, separating it from the subsequent continuously arranged magnetic rings.

[0052] The limiting component 305 adopts a mechanical limiting block, which is fixed on the installation platform and located at the end of the pushing path. It is used to limit the pushing stroke of the pushing component, limit the initial lifting position of the magnetic ring, and ensure that the magnetic ring is accurately positioned directly above the lifting and rotating mechanism 301.

[0053] Preferably, a second position detection component 306 is further provided, which is a through-beam fiber optic sensor installed on the installation platform and distributed at both ends of the magnetic ring pushing path. The through-beam direction extends along the movement trajectory of the pusher component to locate the misaligned magnetic ring and further improve the lifting alignment accuracy.

[0054] II. Frame 400 and transfer assembly mechanism 500 The frame 400 includes a base steel structure, a linear guide rail 401, a horizontal drive module 402, a buffer limit component, and an assembly lifting mechanism 600.

[0055] The base steel structure is a steel frame welded from square tubing, consisting of a bottom rectangular steel plate, two rectangular tubes, and two stiffening plates welded together. A possible structural reference is as follows: the bottom rectangular steel plate measures 610×310×12mm; the two rectangular tubes have a cross-sectional dimension of 120×60×4mm and a length of 582mm, arranged vertically along the length of the bottom steel plate with a distance of 118mm between them; two stiffening plates, measuring 118×100×5mm, are placed between the rectangular tubes to horizontally fill and support the space between them, enhancing structural rigidity.

[0056] The horizontal drive module 402 can employ a magnetically coupled rodless cylinder, bolted to the outside of one of the rectangular tubes and arranged along the length of the tube. The slider of the magnetically coupled rodless cylinder is connected to the moving bracket 503 of the transfer assembly mechanism 500, providing the driving force for the horizontal movement of the platform. Using a magnetically coupled rodless cylinder effectively saves installation space and results in a compact structure. Optionally, the stroke of the magnetically coupled rodless cylinder is 356mm. Alternatively, the horizontal drive module 402 can also employ a servo motor in conjunction with a lead screw module to achieve higher position control accuracy.

[0057] Linear guide rail 401 is a pair of linear guide rails installed on top of two rectangular tubes. The movable bracket 503 cooperates with the guide rails through the slider at the bottom, providing stable lateral movement guidance for the transfer assembly mechanism 500. For example, the guide rail specifications are 23×22mm, and the length is consistent with the length of the rectangular tube.

[0058] The buffer limiters are a pair of hydraulic dampers, installed at both ends on the outside of another rectangular tube, used to limit the horizontal travel of the transfer assembly mechanism 500, providing cushioning and shock absorption at the end of the travel to avoid hard impacts.

[0059] The assembly lifting mechanism 600 employs a cylinder with a guide rod, installed at the center of the bottom steel plate of the base steel structure. Its lifting axis is coaxial with the center of the stud and magnetic ring at the assembly station. It is used to support and lift the magnetic ring upwards during assembly, coordinating with the downward pressing of the stud to complete the insertion. Using a cylinder with a guide rod ensures verticality and torsional resistance during the lifting process. As an alternative, the assembly lifting mechanism 600 can also use a servo electric cylinder for more precise position and speed control.

[0060] like Figure 5 As shown, the transfer assembly mechanism 500 includes a movable support 503, a stud clamping assembly 501, and a magnetic ring clamping assembly 502.

[0061] The movable support 503 is a steel frame welded from steel plates, including a base plate connecting the slider, two vertical trapezoidal plates, and a centrally located vertical rectangular plate. The two vertical trapezoidal plates are symmetrically arranged on the base plate, with the centrally located vertical rectangular plate supported at the top. The vertical rectangular plate is used to install the stud clamping assembly 501, and the trapezoidal plates serve to raise the installation height. In this embodiment, the base plate can be 284×256×12mm in size, and the two vertical trapezoidal plates are 310×120×12mm in size. They are bolted to the base plate by tapping the short side, with the two plates symmetrically arranged with a spacing of 146mm. The vertical rectangular plate is connected to the top of the trapezoidal plates by side bolts.

[0062] The stud clamping assembly 501 is a pneumatic clamp capable of vertical feed, comprising a vertical drive cylinder, an L-shaped mounting plate, and pneumatic grippers. The vertical drive cylinder is vertically fixed to the center of the vertical rectangular plate of the movable bracket 503, with its output end connected to the long side of the L-shaped mounting plate, driving the L-shaped mounting plate to move up and down. The short side of the L-shaped mounting plate is horizontal, and a pneumatic gripper is mounted at its end for clamping the stud head. When the transfer assembly mechanism 500 is in the assembly position, the center of the pneumatic gripper is coaxial with the axis of the lower assembly lifting mechanism 600. For example, the vertical drive cylinder has a stroke of 75mm, and the L-shaped mounting plate has dimensions of 168×75×10mm.

[0063] The magnetic ring clamping assembly 502 is a horizontally extendable pneumatic clamp, including a horizontal drive cylinder, a horizontal mounting plate, and pneumatic grippers. The horizontal drive cylinder is fixed to the center of the base plate of the movable bracket 503, and its output end is connected to the horizontal mounting plate, driving the mounting plate to extend and retract horizontally. Pneumatic grippers are installed below the horizontal mounting plate to clamp the outer circumference of the magnetic ring. In this embodiment, the stroke of the horizontal drive cylinder is 75mm, and the dimensions of the horizontal mounting plate are 152×55×8.5mm.

[0064] III. Work Process and Methods Combination Figure 6-1 to Figure 6-6The overall inspection and assembly process is as follows, corresponding to the automatic inspection and assembly method of the stud-magnetic ring of the present invention: 1. Material distribution piece by piece ( Figure 6-1 ): The upstream vibratory feeder starts, conveying the neatly arranged studs 700 and magnetic rings 800 to the discharge end via the corresponding discharge guide rails; the stud lateral material distribution component 203 and the magnetic ring material distribution component 304 operate respectively, separating the single workpiece at the foremost end laterally to the corresponding inspection station.

[0065] 2. Online detection ( Figure 6-2 ): On the stud side: After the stud is delivered to the end of the guide rail, the molten bead detection component 202 below measures the size of the molten bead 701 through the detection opening to determine whether the stud is qualified.

[0066] On the magnetic ring side: After the magnetic ring is pushed to the lifting station, the lifting and rotating mechanism 301 lifts the magnetic ring to the detection height and drives it to rotate at a constant speed. The magnetic ring defect detection component 302 on the side collects the full circumference contour data of the magnetic ring and determines whether the magnetic ring is qualified. After the detection is completed, the lifting and rotating mechanism falls back and the magnetic ring stays at the waiting station.

[0067] 3. Material sorting and independent material handling ( Figure 6-3 ): The transfer assembly 500 moves horizontally to the material handling station, where the stud clamping assembly 501 and the magnetic ring clamping assembly 502 respectively clamp the corresponding workpieces.

[0068] If the stud fails the inspection: the control unit controls the transfer assembly to move to the throwing position, the stud clamping component releases, and the unqualified stud falls into the discharge chute and enters the waste collection box; then the stud detection and distribution unit re-distributes and inspects, the stud clamping component returns to the picking position to grab again, and the cycle continues until qualified studs are obtained; during this process, the magnetic ring clamping component remains in the clamping state and does not need to be reset.

[0069] If the magnetic ring fails the test: the control unit controls the magnetic ring clamping assembly to move horizontally backward to the throwing position, releases the clamp and lets the unqualified magnetic ring fall into the waste collection box; then the magnetic ring detection and sorting unit re-sorts and detects, the magnetic ring clamping assembly returns to the picking position to grab again, and the cycle continues until a qualified magnetic ring is obtained; during this process, the pin clamping assembly remains in the clamping state and does not need to be reset.

[0070] 4. Synchronization group pair ( Figure 6-4 ): Two sets of fixtures carry qualified workpieces and move horizontally to the assembly station, where they are coaxially aligned with the lower assembly lifting mechanism 600. The control unit issues a synchronization command, and the stud clamping assembly 501 drives the stud to feed downwards. At the same time, the assembly lifting mechanism 600 lifts the magnetic ring upwards. The two axes achieve speed matching through position closed-loop control, and smoothly complete the insertion and assembly of the stud into the magnetic ring.

[0071] 5. Clamp clearance and discharge transfer ( Figure 6-5 , Figure 6-6 ): After assembly, the magnetic ring clamping assembly 502 releases the magnetic ring and retracts horizontally, freeing up space in the outer diameter of the magnetic ring. The downstream robotic arm end effector approaches and clamps the assembled stud-magnetic ring assembly, transferring it to the welding station. The transfer assembly mechanism then resets and begins the next work cycle.

[0072] The above embodiments are preferred solutions, and can be adapted to meet specific needs in practical applications. For example, the material distribution component can be replaced with any suitable structure such as wheel-type material distribution or swing-arm material distribution in the prior art, while only the core detection structure at the end of the discharge guide rail needs to be retained to achieve the detection function of this invention. The horizontal drive method can be selected from cylinders, servo screws, and linear modules. The detection element can be switched between laser sensors, vision cameras, and strain detectors. The driving form of the clamping component can adopt multiple methods such as pneumatic and electric. The overall size of the equipment can be adapted and adjusted according to the specifications of the studs and magnetic rings. All such adjustments do not depart from the technical solution of this invention and fall within the protection scope of this invention.

Claims

1. An automatic detection device for studs and magnetic rings, comprising: The system comprises a base (100), a stud detection unit (200) and a magnetic ring detection unit (300) mounted on the base (100), and a control module. The stud detection unit (200) includes a stud discharge guide rail (201) and a molten bead detection assembly (202). The stud discharge guide rail (201) extends along the feeding direction to receive continuously arranged studs, and has a detection opening at the bottom of its discharge end. The molten bead detection assembly (202) is located below the stud discharge guide rail (201) and is used for online detection of the molten bead size at the stud end of the stud guide rail. The magnetic ring detection unit (300) includes a lifting and rotating mechanism (301) and a control module. The magnetic ring defect detection component (302) is located below the discharge end of the magnetic ring discharge guide rail. It is used to receive the magnetic ring and lift it upwards, while driving the magnetic ring to rotate uniformly around its own axis. The magnetic ring defect detection component (302) is located above and beside the discharge end of the magnetic ring discharge guide rail. It is used to collect the entire outer circumference contour of the rotating magnetic ring online and identify defects. The control module is electrically connected to the molten bead detection component (202), the magnetic ring defect detection component (302), and the lifting and rotating mechanism (301). It is used to determine whether the workpiece is qualified based on the detection data and output a trigger signal for throwing unqualified workpieces.

2. The automatic detection device for studs and magnetic rings as described in claim 1, characterized in that: The stud detection unit (200) also includes a stud transverse material distribution component (203) and a portal frame (204); the portal frame (204) is fixed on the base (100), and its crossbeam spans the discharge end of the stud discharge guide rail (201); the transverse material distribution component (203) is located on the crossbeam of the portal frame (204) and can move laterally along the direction perpendicular to the feeding direction, for laterally separating the single stud at the front end of the stud discharge guide rail (201) to the waiting position.

3. The automatic detection device for studs and magnetic rings as described in claim 2, characterized in that: The stud transverse feeding assembly (203) includes a transverse drive and a slot, the slot opening of which is adapted to the shape of the stud head; the transverse drive is fixed upside down below the crossbeam of the portal frame (204), and its output end is connected to the slot.

4. The automatic detection device for studs and magnetic rings as described in claim 1, characterized in that: The stud discharge guide rail (201) is a U-shaped cross-section guide rail, with an internal cavity to accommodate the stud rod and the stud head exposed on the top surface of the guide rail.

5. The automatic detection device for studs and magnetic rings as described in claim 1, characterized in that: The molten bead detection component (202) is a point laser rangefinder or a spring strain gauge pressure detection component; the laser emitting end of the point laser rangefinder is vertically upward and directly opposite the detection opening of the discharge guide rail (201).

6. The automatic detection device for studs and magnetic rings as described in claim 1, characterized in that: The magnetic ring detection unit (300) also includes a magnetic ring discharge guide rail (303), which is a torsion U-shaped guide rail used to convert the vertically arranged magnetic rings upstream into a horizontal posture and transport them to the discharge end.

7. The automatic detection device for studs and magnetic rings as described in claim 6, characterized in that: The magnetic ring detection unit (300) further includes a magnetic ring distribution component (304) and a limiter (305). The magnetic ring distribution component (304) is located on the side of the discharge end of the magnetic ring discharge guide rail (303), and includes a horizontal drive component and a pusher component connected to the output end of the horizontal drive component, which is used to laterally separate the single magnetic ring at the front end of the guide rail to the lifting position. The limiter (305) is located at the end of the pushing path of the magnetic ring distribution component (304), which is used to limit the initial lifting position of the magnetic ring.

8. The automatic detection device for studs and magnetic rings as described in claim 1, characterized in that: The lifting and rotating mechanism (301) includes a vertical drive and a rotating drive. The rotating drive is fixed to the output end of the vertical drive and moves up and down synchronously with the vertical drive. The output end of the rotating drive is provided with a positioning head that is adapted to the inner hole of the magnetic ring.

9. The automatic detection device for studs and magnetic rings as described in claim 1, characterized in that: The magnetic ring defect detection component (302) is a line laser profile sensor or a structured light camera; the line laser profile sensor or structured light camera is fixed on the base, and its detection end is horizontally aligned with the outer circumferential surface of the magnetic ring after it has been lifted, and collects the outer circumferential profile data of the entire magnetic ring.

10. An integrated automatic detection and assembly device for studs and magnetic rings, comprising a frame (400), an automatic detection device for studs and magnetic rings as described in any one of claims 1-9, a transfer assembly mechanism (500), an assembly lifting mechanism (600), and a control unit, wherein the automatic detection device for studs and magnetic rings is disposed at the feeding end of the frame (400), the transfer assembly mechanism (500) is horizontally reciprocatingly disposed on the frame (400), and the assembly lifting mechanism (600) is disposed on the frame (400) and located directly below the assembly station, for lifting the magnetic ring upwards to cooperate with stud insertion; The transfer assembly mechanism (500) includes independently controlled stud clamping assembly (501) and magnetic ring clamping assembly (502), which are used to clamp the tested studs and magnetic rings respectively and transfer them to the assembly station; The control unit is electrically connected to the stud-magnetic ring automatic detection device, the transfer assembly mechanism (500), and the assembly lifting mechanism (600), respectively. It is used to control the independent throwing process of unqualified workpieces according to the detection results, and to control the pressing action of the stud clamping assembly (501) and the lifting action of the assembly lifting mechanism (600) to be executed synchronously.

11. The integrated automatic detection and assembly device for studs and magnetic rings as described in claim 10, characterized in that: The frame (400) is provided with a linear guide rail (401) extending in the horizontal direction and a horizontal drive module (402). The transfer assembly mechanism (500) also includes a movable bracket (503). The movable bracket (503) is connected to the linear guide rail (401) through a slider. The horizontal drive module (402) is used to drive the movable bracket (503) to reciprocate along the linear guide rail (401). The stud clamping assembly (501) and the magnetic ring clamping assembly (502) are arranged side by side on the movable bracket (503). The stud clamping assembly (501) has a vertical feed degree of freedom, and the magnetic ring clamping assembly (502) has a horizontal extension degree of freedom.

12. The integrated automatic detection and assembly device for studs and magnetic rings as described in claim 10, characterized in that: The control unit is used to: when the stud detection fails, control the stud clamping assembly (501) to move the unqualified stud to the throwing position for release, and return to the waiting position for re-retrieving; when the magnetic ring detection fails, control the magnetic ring clamping assembly (502) to move the unqualified magnetic ring to the throwing position for release, and return to the waiting position for re-retrieving; when a single workpiece fails, the clamping state of the other workpiece remains unchanged.

13. An automatic detection and assembly method for studs and magnetic rings, comprising the following steps: S1 piece-by-piece material separation: Separates the continuously conveyed studs and magnetic rings one by one laterally and positions them to the corresponding inspection station; S2 Online Inspection: The dimensions of the molten beads at the end of the stud are inspected to determine if the beads are qualified; the magnetic ring is driven to rotate uniformly around its own axis, and the outer circumference contour data of the entire magnetic ring is collected to determine whether the magnetic ring is qualified; S3 Material Picking and Independent Disposal: Two independently controlled clamps pick up studs and magnetic rings respectively; if a single workpiece is determined to be unqualified, the corresponding clamp is controlled to carry the unqualified workpiece to the disposal position for disposal, and then returns to the waiting position to pick up a qualified workpiece again, while the other qualified workpiece remains in the clamping state. S4 Synchronous Assembly: Two sets of fixtures carry qualified studs and magnetic rings to the assembly station and are aligned coaxially. The studs are fed downward and the magnetic rings are lifted upward in a synchronous manner to complete the insertion and assembly of the studs and magnetic rings. S5 Discharge Transfer: The magnetic ring clamp loosens and retracts horizontally to avoid the impact, allowing the downstream material handling mechanism to remove the assembled stud-magnetic ring assembly as a whole.

14. The automatic detection and assembly method for studs and magnetic rings as described in claim 13, characterized in that: In step S2, the detection of defects on the outer periphery of the magnetic ring refers to: using a line laser profile sensor or a structured light camera to align with the outer periphery of the magnetic ring, continuously collecting profile data during the uniform rotation of the magnetic ring, unfolding the data into a two-dimensional profile curve, and identifying the abrupt change characteristics of the curve to determine whether there are any breakage or gap defects.

15. The automatic detection and assembly method for studs and magnetic rings as described in claim 13, characterized in that: In step S3, the detection and ejection processes of the stud and the magnetic ring are independent of each other; when both workpieces are unqualified, the corresponding ejection and replenishment actions are executed in sequence.

16. The automatic detection and assembly method for studs and magnetic rings as described in claim 13, characterized in that: In step S4, the downward stroke of the stud and the upward stroke of the magnetic ring are matched by position closed-loop control to maintain a constant relative speed between the two during the insertion process.

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