A detection device for high-performance mine machinery castings

Abstract

The application belongs to the technical field of casting detection, and discloses a kind of detection devices for high-performance mine machinery castings, the device is with gantry frame as bearing base, linear feeding guide rail and high-low position switching telescopic lifting seat are configured to realize automatic feeding and discharging of castings, double-station rotary turntable with positioning and locking structure is driven by motor to complete station cycle switching, double-sided synchronous centering clamping mechanism driven by hydraulic cylinder to lift and lower is assembled by gantry frame, which can unify detection reference and lift castings in the air, multi-axis robot carries coaxial confocal detection module integrated with electromagnetic, ultrasonic, visual and stress detection functions to complete multi-dimensional detection of castings in the whole domain without blind area, the device does not need special clamping tooling, and is suitable for multiple specifications of special-shaped mine castings, the detection reference is stable, without blind area, and the degree of automation is high, which effectively improves the casting detection efficiency and quality control level.

Description

Technical Field

[0001] This invention belongs to the field of casting inspection technology, and specifically relates to a high-performance testing device for mining machinery castings. Background Technology

[0002] Mining machinery castings, as core load-bearing components of mining, crushing, and conveying equipment, are widely used in harsh underground working conditions characterized by heavy loads, strong impacts, and high wear. The internal defects, surface quality, and dimensional accuracy of castings directly determine the operational safety and service life of mining equipment. With the development of mining equipment towards larger and heavier loads, the size and weight of castings such as high-manganese steel jaw plates, high-chromium cast iron hammers, and scraper troughs are continuously increasing, placing higher demands on the automation level, testing efficiency, and comprehensive coverage capabilities of casting inspection equipment. Currently, commonly used casting inspection equipment in the industry mainly consists of fixed inspection tables and single-function inspection modules. The associated loading and unloading structures often rely on manual hoisting and positioning, which can meet the basic inspection needs of conventional small castings and has been applied to some extent in large-scale production lines, providing a basic guarantee for casting quality control.

[0003] In actual production applications, existing testing devices still have technical limitations due to insufficient adaptability. For large, heavy-duty mining castings, manual loading and unloading positioning is inefficient and labor-intensive, and deviations in the placement of castings can easily affect testing accuracy; therefore, clamping fixtures are required. However, the shapes of castings are not uniform, so many different types of clamping fixtures are needed, which is troublesome to change and increases costs. Meanwhile, existing equipment is difficult to achieve unobstructed inspection of the bottom surface of castings, and often adopts manual flipping or hollow support. Flipping operation poses safety hazards, and hollow support is prone to detection interference and blind spots. In addition, most testing devices are only equipped with a single testing module, which cannot simultaneously collect multi-dimensional quality parameters of castings. Furthermore, the clamping mechanism lacks synchronous centering and lifting functions, making it difficult to unify the casting benchmarks for two tests. This fails to meet the requirements of full-dimensional, blind-spot-free, and high-precision automated testing of high-performance mining castings, thus restricting the quality control efficiency and automation upgrade of casting production lines. Summary of the Invention

[0004] In view of the problems raised in the background art above, the purpose of the present invention is to provide a high-performance testing device for mining machinery castings.

[0005] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows: A high-performance testing device for castings in mining machinery includes a gantry frame, a linear feeding guide rail, a rotary table, and a multi-axis robot. The sliding working end of the linear feeding guide rail is equipped with a telescopic lifting seat, which can be raised and lowered horizontally. The working end of the telescopic lifting seat is vertically inserted with a placement plate, which is used to place the castings. The rotary turntable is equipped with a motor at its power end. The rotary turntable is symmetrically provided with two open slots. The size of the open slots matches that of the placement plate. After the placement plate is placed in the open slots, the upper surface of the placement plate and the upper surface of the rotary turntable are at the same level. The gantry frame is equipped with a double-sided clamping mechanism, which is located on both sides above the placement plate in the detection position. The clamping ends on both sides of the double-sided clamping mechanism start and stop synchronously and have the same extension and retraction length. The gantry frame is equipped with a hydraulic cylinder, and the output end of the hydraulic cylinder is connected to the double-sided clamping mechanism. The operation of the hydraulic cylinder drives the double-sided clamping mechanism to move horizontally up and down on the gantry frame. The multi-axis robot output end is equipped with a coaxial confocal detection module, which performs full-area scanning detection on the casting.

[0006] Furthermore, the telescopic support has a low-position loading station and a high-position docking station. The low position is used for convenient loading of the plate and casting, while the high position is used to push the plate horizontally into the slot to complete precise docking. The high and low positions are distinguished to balance the convenience of loading and the accuracy of docking, reduce the difficulty of manual operation, and improve the efficiency of loading and unloading.

[0007] Further, the two sides of the opening slot are provided with embedded positioning telescopic cylinders. The output end of the positioning telescopic cylinder is connected to an insert block. The insert block is provided with a guide slope. The placement plate is provided with a positioning groove whose position and size match the insert block. The guide slope insert block and the positioning groove are locked together to automatically limit the placement plate, prevent movement during the test, and ensure the stability of the test benchmark.

[0008] Furthermore, the bottom of the rotary table is provided with various support components, and all the support components do not hinder the rotation of the rotary table. The bottom support components do not interfere with the rotation of the table, thereby improving the operational stability of the device and adapting to the load-bearing requirements of heavy-duty castings.

[0009] Further defining the double-sided clamping mechanism, it includes a crossbeam slidably mounted on the vertical arm of the gantry frame at both ends. The crossbeam is fixedly connected to two vertical arms, and a load-bearing plate is installed at the end of each of the two vertical arms. A clamping telescopic cylinder is installed on the load-bearing plate, and a clamping block is connected to the output end of the clamping telescopic cylinder. A load-bearing guide rod is integrally connected to the clamping block, and the load-bearing guide rod is slidably installed inside the load-bearing plate. This refines the rigid structure of the clamping mechanism, provides guidance and anti-deviation with the load-bearing guide rod, ensures uniform clamping force, and avoids deformation of the casting during clamping and displacement during lifting.

[0010] Further specifying, the dual-sided clamping mechanism includes, but is not limited to, a gear and rack synchronous centering mechanism, in which the clamping ends on both sides move synchronously toward or away from each other. The gear and rack synchronous centering mechanism is a common clamping mechanism in the prior art, which is easy to understand and can be directly purchased and installed to expand the synchronous centering drive form, ensure that the centers of the two clamping operations are consistent, unify the detection benchmark, and eliminate positional deviations.

[0011] Furthermore, the coaxial confocal detection module integrates an electromagnetic detection unit, an ultrasonic phased array detection unit, a polarization vision detection unit, and a residual stress detection unit. The detection focus of the four units converges at the same spatial point. The four units rotate coaxially, and the four detection units coaxially and confocally focus on the same point, synchronously acquiring multi-parameter data, thereby improving detection accuracy and integration.

[0012] Further defined, the multi-axis robot drives the coaxial confocal detection module to perform multi-pose reciprocating scanning, completing the full-area detection of the upper side before the casting is clamped and lifted, and completing the full-area detection of the bottom surface after the casting is clamped, lifted and suspended in the air. The upper and lower surfaces are detected in stages, and the casting is suspended in the air without obstruction, completely eliminating the bottom surface detection blind spot and achieving full coverage.

[0013] Furthermore, the placement end of the telescopic support is rectangular and has four inserts. The placement plate has holes corresponding to the positions of the inserts. The inserts are inserted into the holes for positioning. The placement plate is easy to assemble and disassemble, and the positioning is accurate, preventing it from falling off during transportation.

[0014] Furthermore, the top of the dual-sided clamping mechanism is equipped with a columnar guide rod, which is slidably mounted on the gantry frame. The columnar guide rod guides the lifting and lowering, improving the stability of the clamping mechanism's lifting and lowering, eliminating shaking, and ensuring clamping and detection accuracy.

[0015] The beneficial effects of using the present invention are as follows: 1. This device uses a linear feeding guide rail with high and low telescopic support seats to realize automated loading and unloading of castings, replace manual hoisting and positioning, reduce labor intensity, adapt to the production line cycle of large heavy-duty mining castings, and improve the efficiency of inspection operations. 2. The open slot combined with the positioning telescopic cylinder locking structure can accurately limit and fix the placement plate, avoid the turntable from moving during the inspection process, stabilize the inspection benchmark, and improve the consistency and reliability of the inspection data. 3. The double-sided clamping mechanism, combined with the hydraulic cylinder lifting structure, can realize the casting to be clamped and centered twice simultaneously, unifying the inspection benchmark. At the same time, the casting is lifted and suspended in the air, and the bottom surface can be inspected without flipping, eliminating blind spots in the inspection and avoiding the safety hazards of flipping operations. 4. The multi-axis robot is equipped with a coaxial confocal inspection module, which can scan castings from multiple angles and collect multi-dimensional quality parameters simultaneously, providing comprehensive inspection coverage and meeting the high-precision inspection needs of complex curved surface mining castings. 5. The detection of this device does not require forced positioning of the workpiece, so there is no manual clamping and positioning process, nor is it necessary to equip it with corresponding clamping fixtures, thus saving costs. Attached Figure Description

[0016] The present invention can be further illustrated by the non-limiting embodiments given in the accompanying drawings; Figure 1 This is a schematic diagram of an embodiment of a high-performance testing device for mining machinery castings according to the present invention; Figure 2 This is a schematic diagram of another perspective of an embodiment of the testing device for high-performance mining machinery castings according to the present invention; The symbols for the main components are explained below: 1. Gantry frame; 2. Linear feeding guide rail; 3. Rotary turntable; 4. Multi-axis robot; 5. Telescopic lifting seat; 6. Placement plate; 7. Motor; 8. Opening slot; 9. Double-sided clamping mechanism; 10. Hydraulic cylinder; 11. Coaxial confocal detection module. Insert post 51; cylindrical guide rod 101; Positioning groove 61; Column hole 62; Positioning telescopic cylinder 81; Insert block 82; Guide slope 83; 91. Horizontal beam; 92. Vertical arm; 93. Load-bearing plate; 94. Clamping telescopic cylinder; 95. Clamping block; 96. Load-bearing guide rod. Detailed Implementation

[0017] To enable those skilled in the art to better understand the present invention, the technical solution of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0018] like Figure 1 , Figure 2As shown, a high-performance testing device for mining machinery castings according to the present invention includes a gantry frame 1, a linear feeding guide rail 2, a rotary table 3 and a multi-axis robot 4. A telescopic lifting seat 5 is installed on the sliding working end of the linear feeding guide rail 2. The telescopic lifting seat 5 can be raised and lowered horizontally. A placement plate 6 is vertically inserted and installed on the working end of the telescopic lifting seat 5. The placement plate 6 is used to place castings. The rotary turntable 3 is equipped with a motor 7 at its power end. The rotary turntable 3 is symmetrically provided with two open slots 8. The size of the open slots 8 matches that of the placement plate 6. After the placement plate 6 is placed into the open slots 8, the upper surface of the placement plate 6 and the upper surface of the rotary turntable 3 are at the same level. The gantry frame 1 is equipped with a double-sided clamping mechanism 9, which is located on both sides above the placement plate 6 in the detection position. The clamping ends on both sides of the double-sided clamping mechanism 9 start and stop synchronously and have the same extension and retraction length. The gantry frame 1 is equipped with a hydraulic cylinder 10, and the output end of the hydraulic cylinder 10 is connected to the double-sided clamping mechanism 9. The operation of the hydraulic cylinder 10 drives the double-sided clamping mechanism 9 to move horizontally up and down on the gantry frame 1. The output end of the multi-axis robot 4 is equipped with a coaxial confocal detection module 11, which performs full-area scanning detection on the casting.

[0019] In this implementation case, the device uses the gantry frame 1 as the fixed bearing and installation benchmark of the whole machine. The linear feeding guide rail 2 is rigidly fixed in the lower working area of ​​the gantry frame 1 in the horizontal direction. The telescopic lifting seat 5 is assembled on the moving end of the linear feeding guide rail 2 in a sliding fit manner. The telescopic lifting seat 5 can move horizontally back and forth at a uniform speed and with precision along the extension direction of the linear feeding guide rail 2. The telescopic lifting seat 5 is equipped with a vertical linear drive structure, which can stably complete the switching between the two vertical working states of low position and high position. The placement plate 6 is connected to the extended working end of the telescopic lifting seat 5 by a vertical plug-in assembly method. The mining machinery casting to be tested can be directly and freely placed on the upper surface of the placement plate 6 without manual position correction, custom-made special positioning fixtures, or additional clamping and fixing. The rotary turntable 3 is rotatably installed in the middle work area of ​​the gantry frame 1 through the rotary support structure. The motor 7 is rigidly connected to the bottom power input position of the rotary turntable 3. The motor 7 is used to drive the rotary turntable 3 to perform intermittent rotational motion around its own vertical central axis at a fixed angle. Two sets of opening slots 8 are symmetrically machined at the outer edge of the rotary turntable 3. The internal contour dimensions of the opening slots 8 are completely matched with the external contour dimensions of the placement plate 6. After the placement plate 6 is horizontally pushed and embedded into the opening slots 8, the upper surface of the placement plate 6 and the upper surface of the rotary turntable 3 remain completely coplanar, with no height difference, no structural interference, and no step obstruction. The double-sided clamping mechanism 9 is symmetrically arranged on the left and right sides of the inspection station, and is located directly above the placement plate 6. The hydraulic cylinder 10 is rigidly fixed vertically on the top crossbeam structure of the gantry frame 1. The lower end of the output rod of the hydraulic cylinder 10 is rigidly connected to the top of the double-sided clamping mechanism 9. When the hydraulic cylinder 10 moves in extension and retraction, it can drive the double-sided clamping mechanism 9 to make a smooth and stable linear lifting and lowering motion in the vertical direction. The left and right clamping ends of the double-sided clamping mechanism 9 adopt a synchronous linkage drive structure. The clamping ends on both sides can extend and retract synchronously, and the extension and retraction strokes on both sides are completely consistent. It can automatically push the casting to the center position of the station to complete the centering clamping and positioning. The multi-axis robot 4 is rigidly fixed on the inner side of the gantry frame 1. The coaxial confocal detection module 11 is rigidly assembled on the end effector of the multi-axis robot 4. The multi-axis robot 4 can drive the coaxial confocal detection module 11 to complete multi-degree-of-freedom, multi-angle, and multi-path posture adjustments, and perform full-area scanning detection on all exposed areas of the casting. The coaxial confocal detection module 11 integrates an electromagnetic detection unit, an ultrasonic phased array detection unit, a polarization vision detection unit, and a residual stress detection unit. The electromagnetic detection unit is used to identify the uniformity of the casting matrix and detect internal non-metallic inclusion defects. The ultrasonic phased array detection unit is used to penetrate the casting matrix and detect internal volumetric and surface defects such as cracks, shrinkage cavities, and shrinkage holes. The polarization vision detection unit is used to identify surface defects such as microcracks, pores, and impact damage on the casting surface. The residual stress detection unit is used to collect residual stress distribution data on the surface and subsurface of the casting. The four detection units share the same central axis, and the detection focus converges at the same spatial point, which can simultaneously collect multi-dimensional quality data at the same detection position. During the operation of the device, the telescopic lifting seat 5 first moves horizontally to the loading station outside the gantry frame 1 and descends to the low position. The operator can place the casting on the placement plate 6 to complete the loading operation. Then, the telescopic lifting seat 5 moves horizontally along the linear loading guide rail 2 to the docking station of the rotary table 3. The telescopic lifting seat 5 rises to the high position and pushes the placement plate 6 horizontally into the opening slot 8 to complete the docking and positioning. After the positioning is completed, the telescopic lifting seat 5 descends to reset and horizontally returns to the loading station to wait for the next operation. Motor 7 drives the rotary table 3 to rotate at a fixed angle, moving the placement plate 6 carrying the casting to the inspection station. Hydraulic cylinder 10 drives the double-sided clamping mechanism 9 to descend vertically to the corresponding height of the casting. The clamping ends of the double-sided clamping mechanism 9 extend synchronously, completing the first centering and positioning of the casting, unifying the spatial reference of the casting in the two inspection processes. Then, it returns to its original position. After positioning, the multi-axis robot 4 starts running, driving the coaxial confocal inspection module 11 to complete multi-angle and multi-pose reciprocating scanning according to the preset inspection path, completely collecting data from the upper surface and side surface of the casting. The detection data of all areas of the contour surface are used to complete the full-area detection of the upper side of the casting. After the upper side detection is completed, the double-sided clamping mechanism 9 clamps again synchronously at the distance of the first run on the lower side and keeps the clamping locked. The hydraulic cylinder 10 drives the double-sided clamping mechanism 9 to move vertically upward, lifting the casting as a whole off the placement plate 6, so that the bottom surface of the casting is completely suspended and without any structural obstruction, forming a complete bottom surface detection space. The multi-axis robot 4 drives the coaxial confocal detection module 11 again to complete the full-area scanning detection of the bottom surface of the casting, realizing the detection of the entire surface of the casting without blind spots. After all the tests are completed, the hydraulic cylinder 10 drives the casting to descend and reset to the surface of the placement plate 6, the double-sided clamping mechanism 9 releases and resets, and the rotary table 3 rotates in the opposite direction to transfer the casting to the loading station, completing a single automated testing cycle. This structure adopts an automated loading and unloading and cyclic workstation switching operation mode, which can be adapted to mining machinery castings of different shapes, weights and specifications. There is no need to change the matching clamping tooling, which effectively reduces the equipment changeover cost and operating cost. The double-sided synchronous clamping structure can ensure that the spatial reference of the casting is completely consistent for two inspections. The suspended inspection method of the casting completely solves the technical problem of blind spots on the bottom surface of traditional inspection equipment. The structure of multiple sets of inspection units coaxial and confocal can simultaneously collect multi-dimensional quality data of the casting. The overall operation is stable, the inspection coverage is comprehensive and the reference consistency is strong, which can be adapted to the continuous automated inspection operation of large-scale casting production lines. The preferred telescopic support 5 has a low-position feeding station and a high-position docking station. The low position is used for convenient feeding of the placement plate 6 and the casting, and the high position is used to push the placement plate 6 horizontally into the opening slot 8 to complete precise docking.

[0020] In this implementation case, the telescopic support 5 can stably switch between two vertical working states: a low-position feeding station and a high-position docking station. In the low-position state, the telescopic support 5 descends to a working height suitable for manual feeding, which facilitates the quick placement and assembly of the placement plate 6 and the casting. In the high-position state, the telescopic support 5 rises to a height that is level with the opening slot 8, which can drive the placement plate 6 to move horizontally to complete the precise docking with the rotary table 3. The structure can flexibly adjust the lifting stroke of the workstation according to the installation height of the production line, and can be equipped with position sensing elements to realize automatic start and stop and precise positioning of workstation switching; The dual-station height adjustment structure simplifies the loading and unloading operation process, reduces the intensity of manual operation, and the high-position precise docking form avoids positional deviation during the transfer of the placement plate 6, thereby improving the stability and docking accuracy of the loading and unloading operation.

[0021] The preferred opening slot 8 has a positioning telescopic cylinder 81 installed on both sides. The output end of the positioning telescopic cylinder 81 is connected to the plug 82. The plug 82 has a guide slope 83. The placement plate 6 has a positioning groove 61 that matches the position and size of the plug 82.

[0022] In this embodiment, the positioning telescopic cylinder 81 is embedded and fixed on the inner walls of both sides of the opening slot 8, the insert block 82 is rigidly connected to the output end of the positioning telescopic cylinder 81, the guide slope 83 is formed on the insertion docking end of the insert block 82, and the positioning groove 61 is correspondingly opened on the side of the placement plate 6. After the placement plate 6 is inserted into the opening slot 8, the positioning telescopic cylinder 81 drives the insert block 82 to extend horizontally, and the guide slope 83 guides the insert block 82 to automatically insert into the positioning groove 61, thus completing the locking and limiting of the placement plate 6. The structure can adjust the extension stroke of the positioning telescopic cylinder 81 according to the specifications of the placement plate 6, and can be equipped with a pressure sensing element to monitor the locking status in real time, so as to avoid excessive locking force and damage to the structure. The guide-type plug-in locking structure can quickly complete the circumferential and radial limiting of the placement plate 6, prevent the placement plate 6 from shifting or deviating during the rotation of the rotary table 3 and the inspection process, stabilize the inspection benchmark of the casting, and improve the consistency and reliability of the inspection data.

[0023] The rotary turntable 3 is preferably equipped with various support components at its bottom, and none of the support components hinder the rotation of the rotary turntable 3.

[0024] In this implementation case, multiple sets of avoidance support components are arranged in a ring at the bottom of the rotary turntable 3. All support components are staggered along the rotation trajectory of the rotary turntable 3 and have no interference with the rotation path of the rotary turntable 3. They can evenly bear the vertical load of the rotary turntable 3 and the casting, and provide stable support for the rotary turntable 3. The support components can adopt the structural form of rolling support or wear-resistant sliding support. The number and load-bearing specifications of the support components can be adjusted according to the heavy load requirements of the casting to reduce rotational friction resistance. The bottom-avoiding support structure enhances the load-bearing rigidity and rotational stability of the rotary table 3, adapting to the load-bearing requirements of heavy-duty mining castings. The interference-free layout ensures smooth rotation of the rotary table 3 and guarantees the accuracy of workstation switching.

[0025] The preferred double-sided clamping mechanism 9 includes a crossbeam 91 that is slidably mounted on the vertical arm of the gantry frame 1 at both ends. The crossbeam 91 is fixedly connected to two vertical arms 92. Each end of the two vertical arms 92 is equipped with a load-bearing plate 93. The load-bearing plate 93 is equipped with a clamping telescopic cylinder 94. The output end of the clamping telescopic cylinder 94 is connected to a clamping block 95. The clamping block 95 is integrally connected to a load-bearing guide rod 96. The load-bearing guide rod 96 is slidably mounted inside the load-bearing plate 93.

[0026] In this embodiment, the two ends of the crossbeam 91 are fitted onto the vertical arm of the gantry frame 1 with a sliding fit. The two vertical arms 92 are rigidly fixed to the lower end face of the crossbeam 91. The load-bearing plate 93 is rigidly fixed to the bottom end of the vertical arm 92. The clamping telescopic cylinder 94 is rigidly fixed to the outside of the load-bearing plate 93. The clamping block 95 is rigidly connected to the output end of the clamping telescopic cylinder 94. The load-bearing guide rod 96 is integrally formed with the clamping block 95. The load-bearing guide rod 96 slides through the guide hole of the load-bearing plate 93 to provide guidance and limit for the clamping action. The clamping block 95 can be replaced with an adapter structure with different contact surface forms to adapt to the clamping requirements of irregularly shaped castings. The load-bearing guide rod 96 can enhance the anti-eccentric load capacity of the clamping structure and prevent clamping sway. The rigid frame clamping structure has a strong load-bearing capacity, and the guiding structure ensures smooth clamping without swaying. The clamping force is uniform, which can prevent the casting from being deformed during clamping. At the same time, it ensures that the casting does not shift during lifting and stabilizes the detection benchmark.

[0027] The preferred double-sided clamping mechanism 9 includes, but is not limited to, a gear and rack synchronous centering mechanism, in which the two clamping ends move synchronously toward or away from each other.

[0028] In this implementation case, the double-sided clamping mechanism 9 adopts a gear and rack synchronous centering drive structure. The clamping transmission structure on both sides completes rigid linkage through gear and rack. After power input, the clamping ends on both sides can synchronously complete the opposite clamping and separation actions. The extension stroke on both sides remains completely consistent, realizing automatic centering clamping. This synchronous drive structure can be replaced with a bidirectional lead screw synchronous transmission structure, which can be equipped with servo drive components to achieve precise adjustment of the clamping stroke and adapt to the clamping requirements of castings of different sizes. The synchronous centering drive structure ensures that the center positions of the casting are completely coincident during the two clamping operations, unifies the casting inspection benchmark, eliminates the influence of positional deviation on inspection accuracy, and has strong structural versatility, making assembly and maintenance convenient.

[0029] The preferred coaxial confocal detection module 11 integrates an electromagnetic detection unit, an ultrasonic phased array detection unit, a polarization vision detection unit, and a residual stress detection unit. The detection focus of the four units converges at the same spatial point, and the four units rotate coaxially.

[0030] In this implementation case, the coaxial confocal detection module 11 integrates an electromagnetic detection unit, an ultrasonic phased array detection unit, a polarization vision detection unit, and a residual stress detection unit. The four detection units are coaxially arranged around the same central axis, and the detection focus converges at the same spatial point. The four units can be synchronously rotated and adjusted around the central axis. The electromagnetic detection unit is used to detect the uniformity of the casting matrix and internal inclusion defects. The ultrasonic phased array detection unit is used to detect internal cracks, shrinkage porosity, and shrinkage cavities in the casting. The polarization vision detection unit is used to detect microcracks, pores, and surface damage defects on the casting surface. The residual stress detection unit is used to detect the distribution of residual stress on the surface and subsurface of the casting. Each detection unit can independently adjust the detection parameters to adapt to the detection needs of mining castings of different materials such as high manganese steel and high chromium cast iron. It can be equipped with a synchronous acquisition module to realize the synchronous processing of multiple data. The multi-detection unit coaxial confocal integrated design can simultaneously collect multi-dimensional quality data at the same detection point without repeated positioning, improving detection integration and accuracy. The coaxial rotation adjustment is suitable for full-area detection of complex curved surface castings.

[0031] The preferred multi-axis robot 4 drives the coaxial confocal detection module 11 to perform multi-pose reciprocating scanning, completing the full-area detection of the upper side before the casting is clamped and lifted, and completing the full-area detection of the bottom surface after the casting is clamped, lifted and suspended.

[0032] In this implementation case, the multi-axis robot 4 plans a multi-pose and multi-path detection trajectory according to the casting contour, and drives the coaxial confocal detection module 11 to complete the reciprocating full-area scanning. When the casting is not lifted, the detection data of all areas of the upper surface and side surface is collected. After the casting is clamped, lifted and suspended, the detection data of all areas of the bottom surface is collected. The detection path can be flexibly adjusted through programming, and high-risk defect areas can be scanned more intensively to meet the full coverage requirements of castings of different specifications. Phased full-area scanning, combined with the suspended structure of the casting, completely eliminates blind spots in the bottom surface of the casting, achieving full-surface inspection without dead angles. Multi-position reciprocating scanning improves the comprehensiveness of inspection coverage and avoids missed defects.

[0033] The preferred telescopic support 5 has a rectangular placement end with four insertion posts 51, and the placement plate 6 has post holes 62 corresponding to the positions of the insertion posts 51.

[0034] In this embodiment, four insert posts 51 are rigidly fixed in a rectangular array at the placement end of the telescopic support seat 5, and the post holes 62 are correspondingly opened at the bottom position of the placement plate 6. When the placement plate 6 is assembled, the post holes 62 are aligned with the insert posts 51 to complete the vertical insertion, thereby realizing the rapid positioning and assembly of the placement plate 6. The insert 51 and the hole 62 can be adjusted to fit the specifications. An anti-slip structure can be added to improve assembly stability. The placement plate 6 can be quickly replaced to fit castings of different sizes. The plug-in positioning assembly structure makes the placement plate 6 easy and efficient to assemble and disassemble, and the positioning is accurate and without deviation, which prevents the placement plate 6 from falling off or shaking during the transfer process and improves the stability of loading and unloading operations.

[0035] Preferably, a cylindrical guide rod 101 is installed on the top of the double-sided clamping mechanism 9, and the cylindrical guide rod 101 is slidably installed on the gantry frame 1.

[0036] In this embodiment, the cylindrical guide rod 101 is rigidly fixed vertically at the top position of the double-sided clamping mechanism 9, and the upper end of the cylindrical guide rod 101 is slidably assembled inside the guide hole of the gantry frame 1, providing vertical guidance and limitation for the lifting and lowering movement of the double-sided clamping mechanism 9. The number and guide length of the cylindrical guide rod 101 can be adjusted, and it can be equipped with wear-resistant bushings to reduce sliding friction and extend the service life of the structure. The vertical guiding design of the columnar guide rod 101 improves the stability of the clamping mechanism's lifting and lowering, eliminates swaying and wobble during the lifting and lowering process, ensures the accuracy of clamping positioning and casting lifting, and further stabilizes the testing benchmark.

[0037] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A high-performance testing device for castings in mining machinery, comprising a gantry frame (1), a linear feeding guide rail (2), a rotary table (3), and a multi-axis robot (4), characterized in that: The sliding working end of the linear feeding guide rail (2) is equipped with a telescopic support seat (5), which is horizontally raised and lowered. The working end of the telescopic support seat (5) is vertically inserted with a placement plate (6), which is used to place the casting. The rotary turntable (3) is equipped with a motor (7) at its power end. The rotary turntable (3) is symmetrically provided with two opening slots (8). The size of the opening slots (8) matches that of the placement plate (6). After the placement plate (6) is placed into the opening slots (8), the upper surface of the placement plate (6) and the upper surface of the rotary turntable (3) are on the same horizontal plane. The gantry frame (1) is equipped with a double-sided clamping mechanism (9). The double-sided clamping mechanism (9) is located on both sides above the placement plate (6) in the detection position. The clamping ends of the double-sided clamping mechanism (9) start and stop synchronously and have the same extension and retraction length. The gantry frame (1) is equipped with a hydraulic cylinder (10). The output end of the hydraulic cylinder (10) is connected to the double-sided clamping mechanism (9). The operation of the hydraulic cylinder (10) drives the double-sided clamping mechanism (9) to move horizontally up and down on the gantry frame (1). The multi-axis robot (4) is equipped with a coaxial confocal detection module (11) at its output end, which performs full-area scanning detection on the casting.

2. The high-performance testing device for mining machinery castings according to claim 1, characterized in that: The telescopic support (5) has a low-position loading station and a high-position docking station. The low position is used for convenient loading of the plate (6) and the casting, and the high position is used to push the plate (6) horizontally into the opening slot (8) to complete the precise docking.

3. The high-performance testing device for mining machinery castings according to claim 1, characterized in that: The opening slot (8) has a positioning telescopic cylinder (81) installed on both sides. The output end of the positioning telescopic cylinder (81) is connected to a plug (82). The plug (82) has a guide slope (83). The placement plate (6) has a positioning groove (61) that matches the position and size of the plug (82).

4. The high-performance testing device for mining machinery castings according to claim 1, characterized in that: The bottom of the rotary turntable (3) is provided with various support components, and none of the support components hinder the rotation of the rotary turntable (3).

5. The high-performance testing device for mining machinery castings according to claim 1, characterized in that: The double-sided clamping mechanism (9) includes a crossbeam (91) that is slidably mounted on the vertical arm of the gantry frame (1) at both ends. The crossbeam (91) is fixedly connected to two vertical arms (92). The ends of the two vertical arms (92) are each equipped with a load-bearing plate (93). The load-bearing plate (93) is equipped with a clamping telescopic cylinder (94). The output end of the clamping telescopic cylinder (94) is connected to a clamping block (95). The clamping block (95) is integrally connected to a load-bearing guide rod (96). The load-bearing guide rod (96) is slidably mounted inside the load-bearing plate (93).

6. The high-performance testing device for mining machinery castings according to claim 1, characterized in that: The dual-sided clamping mechanism (9) includes, but is not limited to, a gear and rack synchronous centering mechanism, in which the clamping ends on both sides move synchronously toward or away from each other.

7. The high-performance testing device for mining machinery castings according to claim 1, characterized in that: The coaxial confocal detection module (11) integrates an electromagnetic detection unit, an ultrasonic phased array detection unit, a polarization vision detection unit, and a residual stress detection unit. The detection focus of the four units converges at the same spatial point, and the four units rotate coaxially.

8. The high-performance testing device for mining machinery castings according to claim 1, characterized in that: The multi-axis robot (4) drives the coaxial confocal detection module (11) to perform multi-pose reciprocating scanning, completing the upper full-area detection before the casting is clamped and lifted, and completing the bottom full-area detection after the casting is clamped, lifted and suspended.

9. The high-performance testing device for mining machinery castings according to claim 5, characterized in that: The telescopic support (5) has four rectangular inserts (51) installed at its placement end, and the placement plate (6) has post holes (62) corresponding to the positions of the inserts (51).

10. A high-performance testing device for mining machinery castings according to claim 1, characterized in that: The top of the double-sided clamping mechanism (9) is equipped with a columnar guide rod (101), which is slidably mounted on the gantry frame (1).

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