Die casting detecting and sorting device

Abstract

The utility model discloses a die casting detecting and sorting device which comprises a rack, a conveying mechanism arranged on the rack, a sorting robot, a visual detecting mechanism and a defective product containing mechanism. The conveying mechanism comprises a moving module and a bearing assembly arranged on the moving module and used for containing products, and the moving module is used for driving the bearing assembly to move back and forth between the feeding and discharging station and the transfer station. The sorting robot is used for grabbing the to-be-detected products from the conveying mechanism to be detected by the visual detection mechanism and placing the detected good products back to the bearing assembly or placing the defective products in a defective bin of the defective product containing mechanism. According to the utility model, the whole process is automatic, and the functions of conveying, detecting and sorting are integrated; the robot and the visual system work cooperatively, and high-precision, high-efficiency and zero-leak-detection quality control is achieved. And in addition, flexible expansibility is achieved, and the device is suitable for detection and sorting of die castings of different specifications by replacing clamps and detection programs.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation testing and sorting technology, specifically to a die-casting parts testing and sorting device. Background Technology

[0002] Die casting involves injecting molten metal (such as copper, zinc, aluminum, or aluminum alloys) into a precision mold using a high-pressure casting process. After cooling and solidification, it forms high-precision parts with complex geometries. This process offers advantages such as high forming efficiency and high material utilization. However, limitations imposed by the flow characteristics of the molten metal, the mold cooling rate, and fluctuations in die casting parameters can lead to defects such as porosity, cracks, shrinkage cavities, and dimensional errors. Typical products are shown in the attached image. Figure 1 The automotive gearbox housing shown has features such as deep cavity, intersecting holes, thin wall, and heat dissipation fins. Although traditional coordinate measuring machine (CMM) measurement is highly accurate, it takes a long time to inspect a single part. Furthermore, during sampling inspection, the die-casting machine needs to be stopped to wait for the inspection results, which increases production costs. In addition, the sampling inspection method is difficult to cover all products in a batch, which makes it easy for defective products to enter the market. Summary of the Invention

[0003] To overcome the above-mentioned defects, this utility model provides a die-casting defect detection and sorting device based on the collaborative operation of visual inspection and sorting robots, which can match the production cycle of the die-casting machine and achieve high-precision, high-efficiency, and zero-missing-inspection quality control.

[0004] The technical solution adopted by this utility model to solve its technical problem is: to provide a die-casting part inspection and sorting device, including a frame, on which a conveying mechanism, a sorting robot, a vision inspection mechanism and a defective product receiving mechanism are arranged;

[0005] The conveying mechanism includes a movable module mounted on the frame and a carrying component mounted on the movable module for placing products. The movable module is used to drive the carrying component to move back and forth between the loading / unloading station and the transfer station. The transfer station and the loading / unloading station are arranged back and forth along the length of the movable module.

[0006] The sorting robot and the vision inspection mechanism are located on the left and right sides of the transfer station, and the defective product receiving mechanism is located at the front end of the transfer station. The sorting robot is used to pick up products to be inspected from the conveying mechanism for inspection by the vision inspection mechanism, and put the inspected good products back into the carrying component, or place the defective products in the defective bin of the defective product receiving mechanism.

[0007] As a further improvement of this utility model, the mobile module includes a base disposed on the frame, a sliding plate slidably fitted on the base for mounting the bearing component, and a drive unit for driving the sliding plate to move back and forth on the base;

[0008] The supporting component includes a mounting plate on the sliding plate, a good product box and a product fixing fixture on the mounting plate, and the good product box and the product fixing fixture are arranged adjacent to each other on the mounting plate.

[0009] As a further improvement of this utility model, the product fixing fixture includes a limiting plate disposed near the rear end of the mounting plate, a movable plate disposed on the front side of the limiting plate and movably connected to the mounting plate, and a first drag chain disposed in the same direction as the base and connected at one end to the movable plate. The first drag chain is positioned on the frame through a first chain plate groove and arranged on the right side of the base.

[0010] The mounting plate is also provided with two cylinder positioning plates, which are arranged opposite each other on the left and right sides of the movable plate. At the same time, a drive cylinder is provided on the opposite side of the two cylinder positioning plates. The piston rods of the two drive cylinders are respectively connected to the left and right ends of the movable plate, and are used to drive the movable plate to move closer to the limiting plate to clamp the product, or move away from the limiting plate to release the product.

[0011] As a further improvement of this utility model, two first photoelectric switches are provided on the left side of the base, and the two first photoelectric switches are respectively arranged at the loading / unloading station and the transfer station.

[0012] The bottom left side of the sliding plate is provided with a first sensing element for triggering the first photoelectric switch.

[0013] As a further improvement of this utility model, the transfer station is equipped with two sensors, which are respectively mounted on the frame via adjustment shafts and arranged on the left and right sides of the moving module.

[0014] As a further improvement of this utility model, the visual inspection mechanism is mounted on the frame via a portal frame bracket, including a linear motor module arranged in the same direction as the moving module and mounted on the right side of the crossbeam of the portal frame bracket, and a visual measuring instrument mounted on the linear motor module. The linear motor module includes a base mounted on the crossbeam, a guide rail mounted on the base, a slide block slidably mounted on the guide rail, and two second photoelectric switches respectively mounted on both ends of the bottom of the base.

[0015] The bottom of the slide is provided with a second sensing element for triggering the second photoelectric switch.

[0016] As a further improvement of this utility model, the top of the crossbeam is provided with a second chain plate groove, and a second drag chain is provided in the second chain plate groove. One end of the second drag chain is fixed to the rear end of the second chain plate groove, and the other end is connected to the slide block through a fixed bracket.

[0017] As a further improvement of this utility model, the sorting robot is a six-joint robot.

[0018] As a further improvement of this utility model, the defective product receiving mechanism also includes an opening and closing unit for opening or closing the top opening of the defective compartment. The opening and closing unit includes two support columns symmetrically arranged on the left and right sides of the defective compartment. Each of the two support columns is provided with an opening and closing cylinder on the side facing the compartment opening. The two opening and closing cylinders are symmetrically arranged in the horizontal direction. At the same time, each of the piston rods of the two opening and closing cylinders is provided with a compartment door, and the two compartment doors are slidably fitted onto the compartment opening.

[0019] The beneficial effects of this utility model are: through full-process automation, integrated conveying, detection and sorting functions; and through the collaborative operation of robots and vision systems, high-precision, high-efficiency and zero-missing-detection quality control is achieved. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the product described in the background section;

[0021] Figure 2 This is a schematic diagram of the structure of this utility model;

[0022] Figure 3 This utility model provides a structural schematic diagram that illustrates the layout of each mechanism.

[0023] Figure 4 This is a schematic diagram of the conveying mechanism of this utility model;

[0024] Figure 5 This is a schematic diagram of the structure of the visual inspection mechanism of this utility model;

[0025] Figure 6 This is a schematic diagram of the defective product receiving mechanism of this utility model.

[0026] Referring to the accompanying drawings, the following explanations are provided:

[0027] 1. Machine frame; A. Loading and unloading station; B. Transfer station; 2. Conveying mechanism;

[0028] 21. Moving module; 211. Base; 212. Sliding plate; 213. Drive unit;

[0029] 214. First photoelectric switch; 215. First sensing element; 22. Bearing assembly; 221. Mounting plate; 222. Good product box; 223. Product fixing fixture; 2231. Limiting plate; 2232. Moving plate; 2233. First drag chain; 2234. First chain plate groove; 2235. Cylinder positioning plate; 2236. Drive cylinder; 23. Sensor; 231. Adjusting shaft; 3. Sorting robot; 4. Vision inspection mechanism; 41. Portal support Frame; 411, crossbeam; 42, linear motor module; 421, base; 422, guide rail; 423, slide; 424, second photoelectric switch; 425, second sensor plate; 426, second chain plate groove; 427, second drag chain; 428, fixed bracket; 43, vision measuring instrument; 5, defective product receiving mechanism; 51, defective bin; 511, bin opening; 52, opening and closing unit; 521, support column; 522, opening and closing cylinder; 523, bin door. Detailed Implementation

[0030] The preferred embodiment of the present invention will be described in detail below with reference to the accompanying drawings.

[0031] See Figures 2 to 5 This utility model provides a die-casting part inspection and sorting device, including a frame 1, on which are mounted a conveying mechanism 2 for transferring products between workstations, a sorting robot 3 for performing product gripping and sorting actions, a vision inspection mechanism 4 for detecting product geometry and surface defects while simultaneously marking defects, and a defective product storage mechanism 5 for classifying and storing defective products. This device is applicable to, but is not limited to, the following: Figure 1 The die-cast products shown are equipped with dynamic visual inspection and six-joint robot sorting technology, which can match the production cycle of the die-casting machine to achieve high-precision, high-efficiency, and zero-missing-inspection quality control. It is understood that the control system of this device (including PLC programming, sensor signal processing, robot motion control, etc.) uses conventional technologies in the field of automation; this description only reflects its functional correlation, and the specific implementation methods are not elaborated. Furthermore, the sorting robot in this device adopts the IR-R7H six-joint flexible robot, which can accommodate multi-angle posture changes of the products.

[0032] The conveying mechanism 2 includes a mobile module 21 mounted on the frame 1 and a carrying component 22 mounted on the mobile module 21 for placing products. The mobile module 21 drives the carrying component 22 to move back and forth between the loading / unloading station A and the transfer station B. The transfer station B (sorting robot operating area) and the loading / unloading station A (manual loading / unloading) are arranged along the length of the mobile module 21 to form a unidirectional logistics closed loop. The sorting robot 3 and the vision inspection mechanism 4 are arranged on the left and right sides of the transfer station B to form a work area where detection and sorting are carried out in parallel. After the sorting robot grabs the product, it turns directly to inspect it, minimizing the path. The defective product receiving mechanism 5 is located at the front end of the transfer station B. When the sorting robot 3 sorts defective products, it does not need to turn around and completes the placement in a single action.

[0033] Specifically, the detection and sorting process of this device is as follows:

[0034] ① The conveyor mechanism 2 moves the product to be inspected to the transfer station B;

[0035] ② Before the sorting robot 3 picks up the product from the carrier component 22 and transfers it to the vision inspection mechanism 4, the vision inspection mechanism 4 simultaneously completes the size measurement and defect marking, and outputs sorting instructions;

[0036] ③ According to the instructions, the sorting robot 3 puts good products back into the carrying component 22, and at the same time the carrying component 22 moves the good products to the loading and unloading station; the defective products are put into the defective warehouse 51 of the defective product receiving mechanism 5 to realize the detection and sorting of products.

[0037] Furthermore, the mobile module 21 includes a base 211 mounted on the frame 1, a sliding plate 212 slidably mounted on the base 211 for mounting the support assembly 22, and a drive unit 213 for driving the sliding plate 212 to move back and forth on the base 211. Specifically, the mobile module can be a TPA-GCR-40 embedded aluminum-based module, and the drive unit adopts a servo motor driven lead screw.

[0038] See Figure 3 The supporting component 22 includes a mounting plate 221 on the sliding plate 212. The mounting plate 221 is provided with a good product box 222 for receiving qualified products and a product fixing fixture 223 for positioning the product to be tested. The good product box 222 and the product fixing fixture 223 are arranged adjacent to each other.

[0039] The product fixing fixture 223 includes a limiting plate 2231 located near the rear end of the mounting plate 221, a movable plate 2232 located on the front side of the limiting plate 2231 and movably connected to the mounting plate 221, and a first drag chain 2233 located in the same direction as the base 211 and connected at one end to the movable plate 2232. The first drag chain 2233 is positioned on the frame 1 through a first chain plate groove 2234 and is arranged on the right side of the base 211. The mounting plate 221 is also provided with two cylinder positioning plates 2235, which are arranged opposite each other on the left and right sides of the movable plate 2232. At the same time, a drive cylinder 2236 is provided on the opposite side of the two cylinder positioning plates 2235. The piston rods of the two drive cylinders 2236 are respectively connected to the left and right ends of the movable plate 2232 to drive the movable plate 2232 to move closer to the limiting plate 2231 to clamp the product, or to move away from the limiting plate 2231 to release the product.

[0040] The limiting plate 2231 is adapted to part of the product structure to limit one side of the product, while the moving plate 2232, driven by the driving cylinder 2236, presses the product against the limiting plate (i.e., forms a contour groove for positioning the product), keeping the product in a grasping state that can be recognized by the sorting robot 3. The first drag chain 2233 is used to carry the air circuit and signal line.

[0041] Furthermore, two first photoelectric switches 214 are provided on the left side of the base 211, and the two first photoelectric switches 214 are respectively arranged at the loading / unloading station A and the transfer station B; a first sensing plate 215 for triggering the first photoelectric switches 214 is provided on the bottom left side of the sliding plate 212. When the carrying component 22 moves to the corresponding station, the first sensing plate 215 enters the detection light path of the corresponding photoelectric switch 214, triggering the control system signal input; the control system controls the sorting robot 3, the vision inspection mechanism 4 and other actuators to move synchronously according to the received signal, realizing precise linkage between station arrival and function activation. Two sensors 23 are provided on the transfer station B, and the two sensors 23 are respectively set on the frame 1 through the adjustment shaft 231 and arranged on the left and right sides of the moving module 21. The sensors 23 can be height adjusted on the adjustment shaft 231 to detect the product status in the good product box and can be used for products of different specifications.

[0042] See Figure 4The visual inspection mechanism 4 is mounted on the frame 1 via a portal frame 41. It includes a linear motor module 42 arranged in the same direction as the moving module 21 and mounted on the right side of the crossbeam 411 of the portal frame 41, and a visual measuring instrument 43 mounted on the linear motor module 42. The linear motor module 42 includes a base 421 mounted on the crossbeam 411, a guide rail 422 mounted on the base 421, a slide block 423 slidably mounted on the guide rail 422, and two second photoelectric switches 424 respectively mounted at both ends of the bottom of the base 421. The bottom of the slide block 423 is provided with a second sensing plate 425 for triggering the second photoelectric switches 424. The top of the crossbeam 411 is provided with a second chain plate groove 426, and a second drag chain 427 is provided within the second chain plate groove 426. One end of the second drag chain 427 is fixed to the rear end of the second chain plate groove 426, and the other end is connected to the slide block 423 via a fixed bracket 428.

[0043] The vision measuring instrument 43 can be an SRI7140 3D laser profile measuring instrument, which is mounted on the slide 423 of the linear motor module 42. In this device, both the product and the camera are dynamic. The camera scans at a high frequency to acquire the cross-sectional profile of the product and extract key measurement data. The sorting robot 3 is used to achieve product posture changes, and the grayscale optimization algorithm of the vision measuring instrument software is used to accurately stitch together the local point cloud acquired by the camera to construct a complete and high-precision 3D point cloud model of the product. The interactive fusion algorithm perfectly merges adjacent overlapping areas. This measuring instrument can detect product dimensions and surface defects in real time and automatically mark them. The sorting robot sorts defective products into the defective warehouse. Through dynamic vision inspection and the coordinated operation of the six-joint robot, the inspection and sorting speed is increased to 30 seconds / piece, matching the production cycle of die-cast parts. Furthermore, the setting of the second photoelectric switch is the same as the working logic of the first photoelectric switch, and will not be elaborated here.

[0044] See Figure 5 The defective product receiving mechanism 5 also includes an opening / closing unit 52 for opening or closing the top opening 511 of the defective compartment 51. The opening / closing unit 52 includes two symmetrically arranged support columns 521 on the left and right sides of the defective compartment 51. Each support column 521 has an opening / closing cylinder 522 on its side facing the opening 511. The two opening / closing cylinders 522 are symmetrically arranged horizontally, and each piston rod of the two opening / closing cylinders 522 has a compartment door 523, which slides onto the opening 511. The defective product receiving mechanism 5 adopts a dual-compartment independent opening / closing design to avoid the risk of material mixing due to sorting errors.

[0045] Specifically, the working process of this device is as follows:

[0046] Feeding: The product is manually placed into the fixing clamp 223 of the bearing component 22;

[0047] Conveying: The mobile module 21 transports the product to the transfer station B;

[0048] Inspection: The sorting robot 3 picks up the products and sends them to the vision inspection unit 4 for full-size measurement and defect detection;

[0049] Sorting:

[0050] Good product: The sorting robot 3 puts it back into the good product box 222, the moving module returns to the loading and unloading station A, the good product is taken out manually, and the process is repeated;

[0051] Defective products: Sorting robot 3 places them into defective warehouse 51, opening and closing unit 52 closes the warehouse door, and moving module 21 returns to loading and unloading station A, repeating the process.

[0052] In summary, the die-casting part inspection and sorting device provided by this utility model is fully automated, integrating conveying, inspection, and sorting functions. The robot and vision system work together to achieve high-precision, high-efficiency, and zero-missing-inspection quality control. Furthermore, it possesses flexible expandability, adapting to the inspection and sorting of die-casting parts of different specifications by changing the fixtures and inspection programs.

[0053] Many specific details have been set forth in the above description to provide a full understanding of this utility model. However, the above description is only a preferred embodiment of this utility model, and this utility model can be implemented in many other ways different from those described herein. Therefore, this utility model is not limited to the specific embodiments disclosed above. Furthermore, any person skilled in the art can make many possible variations and modifications to the technical solution of this utility model using the methods and techniques disclosed above, or modify it into equivalent embodiments with equivalent changes, without departing from the scope of the technical solution of this utility model. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of this utility model, without departing from the content of the technical solution of this utility model, shall still fall within the protection scope of the technical solution of this utility model.

Claims

1. A die casting inspection and sorting apparatus comprising a frame (1), characterized in that: The frame (1) is equipped with a conveying mechanism (2), a sorting robot (3), a vision inspection mechanism (4), and a defective product receiving mechanism (5); The conveying mechanism (2) includes a movable module (21) mounted on the frame (1) and a bearing assembly (22) mounted on the movable module (21) for placing products. The movable module (21) is used to drive the bearing assembly (22) to move back and forth between the loading / unloading station (A) and the transfer station (B). The transfer station (B) and the loading / unloading station (A) are arranged back and forth along the length of the movable module (21). The sorting robot (3) and the vision inspection mechanism (4) are set on the left and right sides of the transfer station (B), and the defective product receiving mechanism (5) is set at the front end of the transfer station (B). The sorting robot (3) is used to grab the product to be inspected from the conveying mechanism (2) for inspection by the vision inspection mechanism (4), and put the good products back into the carrying component (22) after inspection, or place the defective products in the defective bin (51) of the defective product receiving mechanism (5).

2. The die-casting part inspection and sorting device according to claim 1, characterized in that: The mobile module (21) includes a base (211) disposed on the frame (1), a sliding plate (212) slidably mounted on the base (211) for mounting the bearing assembly (22), and a drive unit (213) for driving the sliding plate (212) to move back and forth on the base (211); The supporting component (22) includes a mounting plate (221) disposed on the sliding plate (212), a good product box (222) disposed on the mounting plate (221), and a product fixing fixture (223), wherein the good product box (222) and the product fixing fixture (223) are arranged adjacent to each other on the mounting plate (221).

3. The die-casting part inspection and sorting device according to claim 2, characterized in that: The product fixing fixture (223) includes a limiting plate (2231) disposed near the rear end of the mounting plate (221), a movable plate (2232) disposed on the front side of the limiting plate (2231) and movably connected to the mounting plate (221), and a first drag chain (2233) disposed in the same direction as the base (211) and connected at one end to the movable plate (2232). The first drag chain (2233) is positioned on the frame (1) through a first chain plate groove (2234) and arranged on the right side of the base (211). The mounting plate (221) is also provided with two cylinder positioning plates (2235). The two cylinder positioning plates (2235) are arranged opposite each other on the left and right sides of the moving plate (2232). At the same time, a driving cylinder (2236) is provided on the opposite side of the two cylinder positioning plates (2235). The piston rods of the two driving cylinders (2236) are respectively connected to the left and right ends of the moving plate (2232) to drive the moving plate (2232) to move closer to the limiting plate (2231) to clamp the product, or to move away from the limiting plate (2231) to release the product.

4. The die-casting part inspection and sorting device according to claim 2, characterized in that: Two first photoelectric switches (214) are provided on the left side of the base (211), and the two first photoelectric switches (214) are respectively arranged at the loading and unloading station (A) and the transfer station (B); The bottom left side of the sliding plate (212) is provided with a first sensing plate (215) for triggering the first photoelectric switch (214).

5. The die-casting part inspection and sorting device according to claim 3, characterized in that: The transfer station (B) is equipped with two sensors (23). The two sensors (23) are respectively mounted on the frame (1) via the adjustment shaft (231) and arranged on the left and right sides of the mobile module (21).

6. The die-casting part inspection and sorting device according to claim 3, characterized in that: The visual inspection mechanism (4) is mounted on the frame (1) via a portal frame (41), including a linear motor module (42) arranged in the same direction as the moving module (21) and mounted on the right side of the crossbeam (411) of the portal frame (41), and a visual measuring instrument (43) mounted on the linear motor module (42). The linear motor module (42) includes a base (421) mounted on the crossbeam (411), a guide rail (422) mounted on the base (421), a slide block (423) slidably mounted on the guide rail (422), and two second photoelectric switches (424) respectively mounted on the bottom ends of the base (421). The bottom of the slide (423) is provided with a second sensing plate (425) for triggering the second photoelectric switch (424).

7. The die-casting part inspection and sorting device according to claim 6, characterized in that: The top of the crossbeam (411) is provided with a second chain plate groove (426), and a second drag chain (427) is provided in the second chain plate groove (426). One end of the second drag chain (427) is fixed to the rear end of the second chain plate groove (426), and the other end is connected to the slide (423) through a fixed bracket (428).

8. The die-casting part inspection and sorting device according to claim 1, characterized in that: The sorting robot (3) is a six-joint robot.

9. The die-casting part inspection and sorting device according to claim 1, characterized in that: The defective product receiving mechanism (5) further includes an opening and closing unit (52) for opening or closing the top opening (511) of the defective compartment (51). The opening and closing unit (52) includes two support columns (521) symmetrically arranged on the left and right sides of the defective compartment (51). Each of the two support columns (521) is provided with an opening and closing cylinder (522) on the side facing the opening (511). The two opening and closing cylinders (522) are symmetrically arranged in the horizontal direction. At the same time, each of the piston rods of the two opening and closing cylinders (522) is provided with a compartment door (523). The two compartment doors (523) are slidably fitted onto the opening (511).

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