Magnetic powder flaw detection device

Abstract

According to the magnetic powder inspection detection device provided by the utility model, the workpieces are sequentially conveyed to the magnetization mechanism, the spraying mechanism, the visual inspection mechanism and the demagnetization mechanism through the conveying mechanism for at least one time of magnetic powder inspection, so that the automatic detection of the magnetic powder inspection process of the workpieces is realized, and the detection efficiency is effectively improved; meanwhile, the first visual inspection mechanism, the second visual inspection mechanism and the third visual inspection mechanism are arranged to obtain images of the surfaces of the workpieces sprayed with the magnetic suspension, then images containing magnetic traces can be screened out through the collected images, and therefore the workpieces containing defects can be screened out. Compared with manual detection, visual detection is adopted, the screening efficiency is high, the capability of identifying the workpiece with small cracks by naked eyes is high, the labor cost can be effectively reduced, and the workpiece screening efficiency and quality are improved.

Description

Technical Field

[0001] This utility model relates to the field of magnetic particle testing technology, and in particular to a magnetic particle testing device. Background Technology

[0002] Magnetic particle testing is a non-destructive testing method that utilizes the magnetization properties of ferromagnetic materials to detect surface or near-surface defects. When a ferromagnetic workpiece is magnetized, if defects such as cracks or pores exist on or near the surface, the magnetic permeability at the defect location will be lower than that of the surrounding material, causing distortion of the magnetic field lines. Some magnetic field lines will escape from the workpiece surface, forming a leakage magnetic field. After being sprayed onto the workpiece surface, the leakage magnetic field will attract magnetic powder, forming a visible magnetic trace at the defect location. Therefore, the shape, size, and location of the magnetic trace directly reflect the characteristics of the defect.

[0003] Currently, for magnetized workpieces after spraying magnetic suspension, the process often relies on operator experience, manually inspecting and screening for workpieces with magnetic marking defects. The speed of manual screening is limited by the operator's skill level, and it requires repeated observation of multiple surfaces of the workpiece, resulting in low efficiency in defect screening. Furthermore, the ability to visually identify workpieces with small cracks is poor, and prolonged manual inspection can lead to fatigue, further increasing the risk of misjudgment and resulting in poor screening quality.

[0004] Therefore, in order to improve the efficiency and quality of workpiece screening during magnetic particle testing, it is necessary to provide a new type of magnetic particle testing device. Utility Model Content

[0005] To address the issues of low efficiency and poor inspection quality in manual defect detection of magnetized workpieces in existing technologies, this invention provides a magnetic particle flaw detection device.

[0006] A magnetic particle inspection device includes a frame with a conveying mechanism above it. Above the conveying mechanism, along the conveying direction, are sequentially arranged a magnetizing mechanism for magnetizing the workpiece surface, a spraying mechanism for spraying a magnetic particle suspension, a visual inspection mechanism for acquiring an image of the workpiece surface after spraying the magnetic suspension, and a demagnetizing mechanism for demagnetizing the workpiece. The visual inspection mechanism includes a first visual inspection mechanism located on one side of the conveying mechanism along the conveying direction, a second visual inspection mechanism located on the other side of the conveying mechanism along the conveying direction, and a third visual inspection mechanism located directly above the conveying mechanism along the conveying direction. The first visual inspection mechanism includes a first camera for acquiring an image of the front or left side of the workpiece and a first annular light source located directly below the lens of the first camera. The second visual inspection mechanism includes a second camera for acquiring an image of the rear or right side of the workpiece and a second annular light source located directly in front of the lens of the second camera. The third visual inspection mechanism includes a third camera for acquiring an image of the upper or lower side of the workpiece and a third annular light source located directly in front of the lens of the third camera.

[0007] Furthermore, a plurality of first support rods are fixedly installed on the frame. The first support rods are located on one side of the conveying mechanism, and a bracket is provided above the first support rods. The spraying mechanism, a first lifting slide rod, and a third camera are sequentially arranged on the bracket along the conveying direction. The first lifting slide rod is slidably connected to a first fixed seat, and the second camera and the second ring light source are both installed on the first fixed seat. The third ring light source is connected to the first support rods.

[0008] Furthermore, the third camera is connected to the bracket via a lifting assembly, which includes a lifting cylinder mounted on the bracket, a first piston rod, and a lifting seat. The lifting cylinder is connected to the lifting seat via the first piston rod, and the third camera is mounted on the lifting seat.

[0009] Furthermore, the second camera is connected to the first fixed base via a first movable base, and the first fixed base is provided with a first slide rail arranged along the direction close to or away from the conveying mechanism, and the first movable base is slidably connected to the first slide rail.

[0010] Furthermore, a second lifting slide bar is fixedly installed on the frame. The second lifting slide bar is located on one side of the conveying mechanism and is slidably connected to a second fixed seat. The first camera is connected to the second fixed seat through a second movable seat. The first ring light source is located on one side of the second fixed seat, and the second fixed seat is provided with a second slide rail arranged along the direction close to or away from the conveying mechanism. The second movable seat is slidably connected to the second slide rail.

[0011] Furthermore, the bracket is equipped with an audible and visual alarm for alerting when a defective workpiece is detected.

[0012] Furthermore, the first ring light source, the second ring light source, and the third ring light source each include a lamp body, and the lamp body is provided with a ring-shaped PCB board, on which a plurality of LED white light beads and LED ultraviolet light beads are alternately arranged.

[0013] Furthermore, the spraying mechanism includes a storage tank containing a magnetic powder suspension, and a plurality of outlet pipes are connected to the storage tank, with a nozzle fixedly connected to the bottom end of each outlet pipe.

[0014] Furthermore, the conveying mechanism includes a conveyor frame and a conveyor belt disposed on the conveyor frame, and one end of the conveyor frame is provided with a motor for driving the conveyor belt to rotate; a plurality of clamps for fixing and placing workpieces are equidistantly disposed on the conveyor belt.

[0015] Furthermore, the demagnetizing mechanism is a gate-shaped demagnetizer, which is disposed above the conveying mechanism. The conveying mechanism passes through the inlet end of the gate-shaped demagnetizer and exits through the outlet end of the gate-shaped demagnetizer.

[0016] The beneficial effects of this utility model are as follows: The magnetic particle inspection device provided by this utility model, through a conveying mechanism, sequentially conveys the workpiece to a magnetization mechanism, a spraying mechanism, a visual inspection mechanism, and a demagnetizing mechanism for at least one magnetic particle inspection, thereby automating the magnetic particle inspection process and effectively improving inspection efficiency. Simultaneously, by setting up a first, second, and third visual inspection mechanism to acquire images of the workpiece surface after spraying the magnetic suspension, images containing magnetic traces can be filtered out, thus identifying defective workpieces. Compared to manual inspection, visual inspection screening is highly efficient and has a strong ability to visually identify workpieces with fine cracks, effectively reducing labor costs and improving the efficiency and quality of workpiece screening. Attached Figure Description

[0017] Figure 1 A schematic diagram of the structure of a magnetic particle flaw detection device provided by this utility model;

[0018] Figure 2 for Figure 1 A magnified structural diagram of part A;

[0019] Figure 3 This is a schematic diagram of the structure of LED white light lamp beads and LED ultraviolet light lamp beads.

[0020] Attached Figure Labels

[0021] 1. Frame; 2. Conveying mechanism; 3. Magnetizing mechanism; 4. Spraying mechanism; 41. Liquid storage tank; 42. Liquid outlet pipe; 43. Spray head; 5. Visual inspection mechanism; 51. First camera; 52. First ring light source; 521. LED white light bulb; 522. LED ultraviolet light bulb; 53. Second camera; 54. Second ring light source; 55. Third camera; 56. Third ring light source; 6. Demagnetizing mechanism; 7. Card holder; 8. Second lifting slide bar; 9. Second fixed seat; 91. Second slide rail; 10. Second movable seat; 11. First support rod; 12. Bracket; 13. First lifting slide bar; 14. First fixed seat; 141. First slide rail; 15. Lifting cylinder; 16. First piston rod; 17. Lifting seat; 18. First movable seat; 19. Audible and visual alarm. Detailed Implementation

[0022] To provide a more detailed description of this utility model, the following description is provided in conjunction with the accompanying drawings. It should be noted that the embodiments described below are merely some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

[0023] refer to Figure 1 As shown, a magnetic particle flaw detection device includes a frame 1, a conveying mechanism 2 above the frame 1, and a magnetizing mechanism 3 for magnetizing the surface of a workpiece, a spraying mechanism 4 for spraying magnetic powder suspension, a visual inspection mechanism 5 for acquiring an image of the workpiece surface after spraying the magnetic suspension and performing magnetic trace detection, and a demagnetizing mechanism 6 for demagnetizing the workpiece.

[0024] Specifically, the conveying mechanism 2 includes a conveyor frame and a conveyor belt mounted on the conveyor frame, with a motor at one end of the conveyor frame for driving the conveyor belt to rotate; a plurality of clamping seats 7 for fixing and placing workpieces are equidistantly arranged on the conveyor belt. In this embodiment, the clamping seats 7 are made of insulating rubber material, and the clamping seats 7 are provided with clamping blocks for fixing and placing workpieces.

[0025] During operation, workpieces are fixed in a specific arrangement and placed on the holder 7. The conveyor mechanism 2 then sequentially transfers them to the magnetization mechanism 3, spraying mechanism 4, visual inspection mechanism 5, and demagnetization mechanism 6. When a workpiece moves to one of these mechanisms, the conveyor mechanism 2 pauses for a preset time, allowing each mechanism to perform its corresponding operation until the workpiece has passed through all mechanisms, completing the first round of inspection. Subsequent rounds of inspection can be performed by changing the placement arrangement, ensuring that defects are detected on all surfaces of the workpiece. Automated inspection is more efficient than manual inspection, and the inspection quality is more consistent, effectively reducing labor costs and improving production quality.

[0026] The magnetization mechanism 3 includes a housing (not shown in the figure), through which the conveying mechanism 2 passes. A circumferential magnetic yoke coil is provided at the inlet and outlet ends of the housing, and a longitudinal magnetic yoke coil is provided on each of the left and right sides of the conveying mechanism inside the housing for magnetizing the entire workpiece.

[0027] The spraying mechanism 4 includes a storage tank 41 containing a magnetic powder suspension. Several outlet pipes 42 are connected to the storage tank 41, and each outlet pipe 42 is fixedly connected to a nozzle 43 at its bottom end. In this embodiment, the storage tank 41 is provided with an inlet pipe and a transparent observation window for observing the liquid level inside the storage tank 41.

[0028] The storage tank 41 ensures a stable supply of magnetic powder liquid, and the outlet pipe 42 and nozzle 43 can evenly spray the magnetic powder suspension onto the workpiece, ensuring the formation of magnetic marks at the defects of the workpiece, which is conducive to improving the inspection efficiency of subsequent workpieces; the inlet pipe facilitates timely replenishment, and the transparent observation window can monitor the liquid level in real time, avoid spraying interruption, and ensure the quality of inspection.

[0029] refer to Figure 1 and Figure 2 As shown, the visual inspection mechanism 5 includes a first visual inspection mechanism disposed on one side of the conveying mechanism 2 along the conveying direction, a second visual inspection mechanism disposed on the other side of the conveying mechanism 2 along the conveying direction, and a third visual inspection mechanism disposed directly above the conveying mechanism 2 along the conveying direction.

[0030] The first visual inspection mechanism includes a first camera 51 for acquiring images of the front or left side of the workpiece, and a first ring light source 52 positioned directly below the lens of the first camera 51. The second visual inspection mechanism includes a second camera 53 for acquiring images of the rear or right side of the workpiece, and a second ring light source 54 positioned directly in front of the lens of the second camera 53. The third visual inspection mechanism includes a third camera 55 for acquiring images of the upper or lower side of the workpiece, and a third ring light source 56 positioned directly in front of the lens of the third camera 55.

[0031] In this embodiment, the magnetized workpiece, which has been sprayed with magnetic levitation liquid, sequentially passes through a first visual inspection mechanism, a second visual inspection mechanism, and a third visual inspection mechanism to acquire images of the workpiece surface. These images are then processed through a pre-set program to filter out images containing magnetic traces, thus identifying defective workpieces. Compared to manual inspection, visual inspection is highly efficient and has a strong ability to visually identify workpieces with small cracks, effectively reducing labor costs and improving the efficiency and quality of workpiece screening.

[0032] In this embodiment, the first camera 51, the second camera 53, and the third camera 55 are all wide-angle cameras. When the workpiece is placed, the parts that do not need to be inspected are fixed on the mounting bracket 7. The wide-angle cameras can cooperate to complete the acquisition of a comprehensive image of the surface that needs to be inspected. At this time, a comprehensive defect screening of the workpiece can be completed in just one round of inspection.

[0033] In practical use, because the workpiece needs to be fixed during transport and sprayed with magnetic powder suspension, it is possible that one side may not be sprayed with magnetic powder suspension or an image of that side may not be acquired, resulting in incomplete detection. Therefore, to ensure comprehensive acquisition of workpiece images, this device can perform two inspections with different placement and fixing methods. In the first inspection, with the workpiece upright, the first camera 51 acquires an image of the front side of the workpiece, the second camera 53 acquires an image of the rear side, and the third camera 55 acquires an image of the top side, completing the first round of workpiece defect detection. In the second inspection, with the workpiece upside down, the first camera 51 acquires an image of the left side, the second camera 53 acquires an image of the right side, and the third camera 55 acquires an image of the bottom side, completing the second round of workpiece defect detection. By performing two rounds of workpiece defect detection, comprehensive acquisition of images of any possible defects on the workpiece surface can be ensured, thereby improving the accuracy and quality of the inspection.

[0034] Specifically, a second lifting slide bar 8 is fixedly installed on the frame 1. The second lifting slide bar 8 is located on one side of the conveying mechanism 1 and is slidably connected to a second fixed seat 9. The first camera 51 is connected to the second fixed seat 9 through a second movable seat 10. The first ring light source 52 is disposed on one side of the second fixed seat 9, and the second fixed seat 9 is provided with a second slide rail 91 arranged along the direction close to or away from the conveying mechanism 2. The second movable seat 10 is slidably connected to the second slide rail 91.

[0035] The second movable seat 10 can slide up and down with the second fixed seat 9 on the second lifting slide bar 8, and the first ring light source 52 moves with the second fixed seat 9, thereby adjusting the height of the first camera 51 and the first ring light source 52, and adjusting the vertical distance between the first camera 51 and the first ring light source 52 and the workpiece. By sliding the second movable seat 10 on the second slide rail 91 of the second fixed seat 9, the first camera 51 can move in a direction closer to or further away from the conveying mechanism 2, adjusting the horizontal distance between the first camera 51 and the workpiece.

[0036] A plurality of first support rods 11 are fixedly installed on the frame 1. The first support rods 11 are located on one side of the conveying mechanism 2, and a bracket 12 is provided above the first support rods 11. The spraying mechanism 4, a first lifting slide rod 13 and a third camera 55 are sequentially arranged on the bracket 12 along the conveying direction. The first lifting slide rod 13 is slidably connected to a first fixed seat 14, and the second camera 53 and the second ring light source 54 are both installed on the first fixed seat 14. The third ring light source 56 is connected to the first support rods 11.

[0037] The second camera 53 and the second ring light source 54 can slide up and down with the first fixed base 14 on the second lifting slide bar 8, thereby adjusting the height of the second camera 53 and the second ring light source 54 and adjusting the vertical distance between the second camera 53 and the second ring light source 54 and the workpiece.

[0038] The third camera 55 is connected to the bracket 12 via a lifting assembly (not shown in the figure). The lifting assembly includes a lifting cylinder 15, a first piston rod 16, and a lifting seat 17 mounted on the bracket 12. The lifting cylinder 15 is connected to the lifting seat 17 via the first piston rod 16, and the third camera 55 is mounted on the lifting seat 17.

[0039] The lifting cylinder 15 drives the first piston rod 16 to lift the lifting seat 17, causing the third camera 55 to rise and fall in a direction perpendicular to the conveying mechanism 2, thereby adjusting the distance between the third camera 55 and the workpiece.

[0040] The second camera 53 is connected to the first fixed base 14 via a first movable base 18. The first fixed base 14 is provided with a first slide rail 141 arranged in a direction close to or away from the conveying mechanism 2. The first movable base 18 is slidably connected to the first slide rail 141.

[0041] The second camera 53 can be moved along the direction of approaching or moving away from the conveying mechanism 2 by sliding the first movable seat 18 on the first slide rail 141 of the first fixed seat 14, thereby adjusting the horizontal distance between the second camera 53 and the workpiece.

[0042] refer to Figure 3As shown, the first ring light source 52, the second ring light source 54, and the third ring light source 56 each include a lamp body. The lamp body is provided with a ring-shaped PCB board, and a plurality of LED white light beads 521 and LED ultraviolet light beads 522 are alternately arranged on the ring-shaped PCB board.

[0043] In practical applications, when the magnetic powder suspension contains fluorescent agents, the ring light source uses LED ultraviolet lamp beads 522 for illumination, forming a clear fluorescent magnetic trace image on the workpiece surface. When the magnetic powder suspension does not contain fluorescent agents, the ring light source uses LED white lamp beads 521 for illumination to observe the distribution of non-fluorescent magnetic powder, facilitating the camera's acquisition of magnetic trace images of the workpiece. LED white lamp beads 521 can also provide supplementary lighting during image acquisition.

[0044] The bracket 12 is equipped with an audible and visual alarm 19 for alerting when a defective workpiece is detected. When the visual inspection mechanism captures an image containing magnetic traces and determines that the workpiece is defective, the audible and visual alarm 19 can be triggered in time to issue a warning, so that the user notices the existence of the defective workpiece and removes it in time.

[0045] The demagnetizing mechanism 6 is a gate-shaped demagnetizer, which is positioned above the conveying mechanism 2. The conveying mechanism 2 passes through the entrance end of the gate-shaped demagnetizer and exits through its exit end. After visual inspection, the conveying mechanism 2 transports the workpiece through the gate-shaped demagnetizer for demagnetization, thereby reducing surface magnetic powder residue and preventing magnetism from affecting subsequent processing or use of the workpiece.

[0046] In practical use, the end of the conveying mechanism 2 is also provided with a magnetic powder cleaning and collection mechanism for cleaning and collecting the card holder 7 and the magnetic powder scattered on the conveying mechanism 2.

[0047] The preferred embodiments of this utility model disclosed above are merely illustrative of the present utility model and do not limit the utility model to the specific implementations described. Obviously, other modifications and variations can be made based on the content of this specification. The embodiments selected and specifically described in this specification are intended to better explain the principles and practical applications of this utility model, thereby enabling those skilled in the art to better understand and utilize it. They are not intended to limit the utility model, and any simple modifications to this utility model fall within the protection scope of this utility model.

Claims

1. A magnetic particle inspection device, characterized in that, It includes a frame, and a conveying mechanism is provided above the frame. Above the conveying mechanism, along the conveying direction, there are a magnetizing mechanism for magnetizing the surface of the workpiece, a spraying mechanism for spraying magnetic powder suspension, a visual inspection mechanism for acquiring an image of the workpiece surface after spraying magnetic suspension for magnetic trace detection, and a demagnetizing mechanism for demagnetizing the workpiece. The visual inspection mechanism includes a first visual inspection mechanism disposed on one side of the conveying mechanism along the conveying direction, a second visual inspection mechanism disposed on the other side of the conveying mechanism along the conveying direction, and a third visual inspection mechanism disposed directly above the conveying mechanism along the conveying direction. The first visual inspection mechanism includes a first camera for acquiring magnetic trace images of the front or left side of a workpiece, and a first ring light source positioned directly below the lens of the first camera; the second visual inspection mechanism includes a second camera for acquiring magnetic trace images of the rear or right side of a workpiece, and a second ring light source positioned directly in front of the lens of the second camera; the third visual inspection mechanism includes a third camera for acquiring images of the upper or lower side of a workpiece, and a third ring light source positioned directly in front of the lens of the third camera.

2. The magnetic particle inspection device according to claim 1, characterized in that, A plurality of first support rods are fixedly installed on the frame. The first support rods are located on one side of the conveying mechanism, and a bracket is provided above the first support rods. The spraying mechanism, a first lifting slide rod, and a third camera are sequentially arranged on the bracket along the conveying direction. The first lifting slide rod is slidably connected to a first fixed seat, and the second camera and the second ring light source are both installed on the first fixed seat. The third ring light source is connected to the first support rods.

3. The magnetic particle inspection device according to claim 2, characterized in that, The third camera is connected to the bracket via a lifting assembly. The lifting assembly includes a lifting cylinder, a first piston rod, and a lifting seat mounted on the bracket. The lifting cylinder is connected to the lifting seat via the first piston rod, and the third camera is mounted on the lifting seat.

4. The magnetic particle inspection device according to claim 2, characterized in that, The second camera is connected to the first fixed base via a first movable base. The first fixed base is provided with a first slide rail arranged along the direction close to or away from the conveying mechanism. The first movable base is slidably connected to the first slide rail.

5. The magnetic particle inspection device according to claim 1, characterized in that, A second lifting slide bar is also fixedly installed on the frame. The second lifting slide bar is located on one side of the conveying mechanism and is slidably connected to a second fixed seat. The first camera is connected to the second fixed seat through a second movable seat. The first ring light source is located on one side of the second fixed seat, and the second fixed seat is provided with a second slide rail arranged along the direction close to or away from the conveying mechanism. The second movable seat is slidably connected to the second slide rail.

6. The magnetic particle inspection device according to claim 2, characterized in that, The bracket is equipped with an audible and visual alarm to alert the user when a defective workpiece is detected.

7. The magnetic particle inspection device according to claim 1, characterized in that, The first, second, and third annular light sources each include a lamp body, and the lamp body is provided with an annular sheet PCB board. A plurality of white LED beads and ultraviolet LED beads are alternately arranged on the annular sheet PCB board.

8. The magnetic particle inspection device according to claim 1, characterized in that, The spraying mechanism includes a storage tank containing magnetic powder suspension, and several outlet pipes are connected to the storage tank. Each outlet pipe is fixedly connected to a nozzle at its bottom end.

9. A magnetic particle inspection device according to claim 1, characterized in that, The conveying mechanism includes a conveyor frame and a conveyor belt mounted on the conveyor frame, and one end of the conveyor frame is provided with a motor for driving the conveyor belt to rotate; a plurality of clamps for fixing and placing workpieces are equidistantly arranged on the conveyor belt.

10. A magnetic particle inspection device according to claim 1, characterized in that, The demagnetizing mechanism is a gate-shaped demagnetizer, which is positioned above the conveying mechanism. The conveying mechanism passes through the entrance end of the gate-shaped demagnetizer and exits through the exit end of the gate-shaped demagnetizer.

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