Nut welding error-proofing detection device

Abstract

The utility model discloses a nut welding error-proofing detection device which comprises a main controller, a position detection assembly, a thickness detection assembly, an alarm module, a man-machine interaction module and an execution module. The position detection assembly adopts a magnetic railing ruler, and a magnetic railing ruler magnetic head is connected with the positioning pin through a positioning pin connecting rod and used for detecting the displacement of the positioning pin; the thickness detection assembly adopts a resistance ruler and is used for detecting the descending position of the upper electrode. The main controller adopts a GD32F450 chip, receives and processes signals of the two assemblies, and controls the audible and visual alarm to give an alarm, the industrial HMI to display information and the pneumatic electromagnetic valve to drive the air cylinder to act when the signals are abnormal. The device is low in misjudgment rate, high in precision and fast in response through dual-redundancy detection, can detect neglected installation, reverse installation and stacking installation of nuts, and is suitable for an automatic welding production line.

Description

Technical Field

[0001] This utility model relates to the technical field of automated welding inspection equipment, and in particular to a nut welding error prevention and inspection device. Background Technology

[0002] On nut welding production lines, the installation quality of nuts directly affects the assembly accuracy and performance of subsequent products. In actual production, problems such as missing nuts, reverse installation, and overlapping placement often occur. Traditional manual inspection methods are inefficient and easily affected by human factors, while single-sensor detection lacks cross-validation mechanisms, resulting in a high false positive rate and failing to meet the production requirements of high precision and high reliability. Therefore, there is an urgent need for a nut welding error-proofing inspection device that integrates multiple sensors and can achieve multiple detection functions. Utility Model Content

[0003] To address the problems of missed detection, high false positive rate, and insufficient reliability in existing nut welding inspection, this utility model provides a nut welding error prevention detection device. Through the collaborative work of multiple sensors, it can accurately detect missing, reversed, and overlapping nuts, thereby improving inspection reliability and production efficiency.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a nut welding error prevention detection device, comprising a main controller, a position detection component, a thickness detection component, an alarm module, a human-machine interaction module, and an execution module; the position detection component and the thickness detection component are both electrically connected to the main controller, and the main controller is electrically connected to the alarm module, the human-machine interaction module, and the execution module respectively; the position detection component includes a magnetic grating ruler, and the thickness detection component includes a resistance ruler.

[0005] As a further improvement to the technical solution of this utility model, the magnetic scale includes a magnetic scale head and a positioning pin, and the positioning pin is connected to the magnetic scale head through a positioning pin connecting rod; the magnetic scale has an accuracy of 5μm and outputs 50 pulses per millimeter.

[0006] As a further improvement to the technical solution of this utility model, the accuracy of the resistance ruler is ±0.05%, and the total stroke is 175mm.

[0007] As a further improvement to the technical solution of this utility model, the main controller adopts the GD32F450 chip; the main controller is provided with a timer encoder interface and an ADC sampling interface.

[0008] As a further improvement to the technical solution of this utility model, the alarm module is an audible and visual alarm.

[0009] As a further improvement to the technical solution of this utility model, the execution module includes a pneumatic solenoid valve; the pneumatic solenoid valve is respectively connected to a lower electrode cylinder and an upper electrode pressurizing cylinder.

[0010] As a further improvement to the technical solution of this utility model, the human-machine interaction module is an industrial HMI, which is electrically connected to the main controller.

[0011] As a further improvement to the technical solution of this utility model, the magnetic scale is model MHO-H200.

[0012] As a further improvement to the technical solution of this utility model, the resistance ruler is model LWF-175, and the probe of the resistance ruler is provided with an oil-proof silicone sleeve.

[0013] As a further improvement to the technical solution of this utility model, it also includes an electrode grip and an electrode cooling water jacket. The diameter and length of the electrode grip can be customized, and the electrode cooling water jacket is installed in conjunction with the electrode grip.

[0014] This utility model has the following beneficial effects:

[0015] Dual-sensor collaborative detection: Through cross-verification of magnetic grating ruler and resistance ruler, a dual-redundant detection mechanism is formed, which greatly reduces the false judgment rate, which can be controlled below 0.01%.

[0016] High detection accuracy: The magnetic scale has an accuracy of 5μm, and the highest accuracy can reach 2μm when combined with the timer encoder function of the main controller; the resistance scale has an accuracy of 0.1mm after digital filtering, which can accurately identify the installation status of nuts.

[0017] Fast response speed: The device automatically matches the welding sequence, and the response time from detection to output control signal is less than 10ms, which does not affect the normal welding cycle.

[0018] Adaptable to harsh environments: The resistance ruler probe is equipped with an oil-proof silicone sleeve to adapt to lubricated environments; regular demagnetization of the magnetic scale ensures long-term detection accuracy.

[0019] Comprehensive alarm functions: Multiple alarm modes are achieved through audible and visual alarms and industrial HMI, which can display specific alarm information such as no welded workpiece, workpiece exceeding positive tolerance, and workpiece exceeding negative tolerance, facilitating quick troubleshooting. Attached Figure Description

[0020] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0021] Figure 1 is a three-dimensional structural schematic diagram of a nut welding error prevention and detection device according to the present invention;

[0022] Figure 2 is one of the structural schematic diagrams of the position detection component of this utility model;

[0023] Figure 3 is a second structural schematic diagram of the position detection component of this utility model;

[0024] Figure 4 This is a schematic diagram of the thickness detection component of this utility model;

[0025] Figure 5 is a structural block diagram of a nut welding error prevention detection device according to this utility model.

[0026] In the diagram: 1-Main controller (GD32F450); 2-Magnetic scale; 21-Magnetic scale head; 22-Positioning pin; 23-Positioning pin connecting rod; 3-Resistance scale; 4-Audible and visual alarm; 5-Industrial HMI; 6-Pneumatic solenoid valve; 7-Lower electrode cylinder; 8-Upper electrode pressurizing cylinder; 9-Electrode grip; 10-Electrode cooling water jacket; 11-Positioning pin lifting cylinder; 12-Upper electrode; 13-Lower electrode. Detailed Implementation

[0027] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The illustrative embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention.

[0028] It should be noted that all directional indicators (such as up, down, left, right, front, back, upper end, lower end, top, bottom, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0029] In this utility model, unless otherwise explicitly specified and limited, the term "connection" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0030] Furthermore, in this utility model, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. If the combination of technical solutions is contradictory or impossible to implement, such a combination should be considered non-existent and not within the scope of protection claimed by this utility model.

[0031] This utility model provides the following technical solution:

[0032] Reference Figures 1 to 5 A nut welding error prevention detection device includes a main controller 1, a position detection component, a thickness detection component, an alarm module, a human-machine interaction module, and an execution module. The position detection component and the thickness detection component are both electrically connected to the main controller 1. The main controller 1 is electrically connected to the alarm module, the human-machine interaction module, and the execution module. The position detection component includes a magnetic ruler 2, and the thickness detection component includes a resistance ruler 3. Specifically, the position detection component and the thickness detection component are both electrically connected to the main controller 1 to detect the position and thickness information of the nut and send them to the main controller 1. The main controller 1 is electrically connected to the alarm module, the human-machine interaction module, and the execution module to receive and process the position and thickness information. When an abnormality is detected, the main controller controls the alarm module to issue an alarm signal, displays the alarm information through the human-machine interaction module, and controls the execution module to perform corresponding actions.

[0033] Specifically, in this embodiment, the magnetic scale 2 includes a magnetic scale head 21 and a positioning pin 22. The positioning pin 22 is connected to the magnetic scale head 21 via a positioning pin connecting rod 23. The magnetic scale 2 has an accuracy of 5μm and outputs 50 pulses per millimeter. The magnetic scale head 21 is used to detect the actual displacement of the positioning pin 22.

[0034] Specifically, in this embodiment, the resistance ruler 3 has an accuracy of ±0.05% and a total stroke of 175mm. The resistance ruler 3 is used to detect the descent position of the upper electrode.

[0035] Specifically, in this embodiment, the main controller 1 uses a GD32F450 chip; the main controller 1 is equipped with a timer encoder interface and an ADC sampling interface. It should be noted that the main controller 1 has both timer encoder and ADC sampling functions. The timer encoder function is used to process the signal from the position detection component, with a maximum accuracy of 2μm; the ADC sampling function is used to digitally filter the signal from the thickness detection component, achieving an accuracy of 0.1mm.

[0036] Specifically, in this embodiment, the alarm module is an audible and visual alarm 4. It should be noted that the alarm information includes alarm codes, which at least include no welded workpiece, workpiece exceeding positive tolerance, and workpiece exceeding negative tolerance.

[0037] Specifically, in this embodiment, the execution module includes a pneumatic solenoid valve 6; the pneumatic solenoid valve 6 is connected to a lower electrode cylinder 7 and an upper electrode pressurizing cylinder 8. It should be noted that the pneumatic solenoid valve 6 is used to drive the lower electrode cylinder 7 and the upper electrode pressurizing cylinder 8 to operate.

[0038] Specifically, in this embodiment, the human-machine interface module is an industrial HMI5, which is electrically connected to the main controller 1. The industrial HMI5 is used to display detection data and alarm information, as well as to set parameters.

[0039] Specifically, in this embodiment, the magnetic scale 2 is model MHO-H200.

[0040] Specifically, in this embodiment, the resistance ruler 3 is model LWF-175, and the probe of the resistance ruler 3 is provided with an oil-proof silicone sleeve.

[0041] Specifically, in this embodiment, the solution also includes an electrode grip 9 and an electrode cooling water jacket 10. The diameter and length of the electrode grip 9 can be customized, and the electrode cooling water jacket 10 is installed in conjunction with the electrode grip 9.

[0042] The present invention will be further described in detail below with reference to the accompanying drawings:

[0043] Implementation Case:

[0044] As shown in Figures 1 to 5, a nut welding error prevention detection device mainly consists of a main controller 1, a position detection component, a thickness detection component, an alarm module, a human-machine interaction module, an execution module, and mechanical structural components.

[0045] The mechanical structure components include an electrode holder 9, an electrode cooling water jacket 10, a positioning pin 22, a positioning pin connecting rod 23, and a positioning pin lifting cylinder 11. The diameter and length of the electrode holder 9 can be customized according to actual welding requirements. The electrode cooling water jacket 10 is installed in conjunction with the electrode holder 9 and is used for cooling the electrode during the welding process. The positioning pin 22 is connected to the magnetic head 21 of the magnetic scale through the positioning pin connecting rod 23. The positioning pin lifting cylinder 11 drives the positioning pin 22 to move up and down.

[0046] The position detection component uses the Atom MHO-H200 magnetic scale 2. Its magnetic scale head 21 detects the actual displacement of the positioning pin 22 to achieve anti-reverse and error detection of the nut. The magnetic scale 2 has an accuracy of 5μm and outputs 50 pulses per millimeter, which can accurately capture the minute displacement changes of the positioning pin 22.

[0047] The thickness detection component uses a Jiasheng LWF-175 resistance ruler 3 to detect the descent position of the upper electrode 12, thereby detecting incorrect overlapping of nuts. Its accuracy is ±0.05%, and the total stroke is 175mm. The probe of the resistance ruler 3 is equipped with an oil-proof silicone sleeve, which can effectively resist oil contamination in the lubrication environment.

[0048] The main controller 1 uses a GD32F450 chip. Its timer encoder interface is connected to the magnetic scale 2 to receive and process position detection signals, achieving a displacement detection accuracy of up to 2μm. Its ADC sampling interface is connected to the resistance scale 3, and through digital filtering, the thickness detection accuracy reaches 0.1mm.

[0049] The alarm module is an audible and visual alarm 4. When an abnormality is detected, it can issue an audible and visual alarm signal to promptly remind the operator.

[0050] The human-machine interface module is an industrial HMI5, used to display detection data, alarm information (such as no welded workpiece, workpiece exceeding positive tolerance, workpiece exceeding negative tolerance, etc.) and to set parameters (such as zero point calibration, tolerance range setting, etc.).

[0051] The execution module includes a pneumatic solenoid valve 6, which is connected to the lower electrode cylinder 7 and the upper electrode pressurizing cylinder 8 respectively, and is used to receive control signals from the main controller 1 to drive the lower electrode 13 and the upper electrode 12.

[0052] Working principle:

[0053] Test preparation: Before starting the device, zero-point calibration is performed using the industrial HMI5 (can be performed manually or automatically), setting the rated values ​​for nut installation position, thickness, and positive and negative tolerance ranges; the magnetic scale 2 is demagnetized every 6 months to ensure test accuracy.

[0054] Pre-welding inspection: After the workpiece to be welded is placed in place, the upper electrode pressurizing cylinder 8 drives the upper electrode to descend. After the pre-pressurization time ends, the resistance ruler 3 detects the descending position of the upper electrode and obtains relevant information about the nut thickness. At the same time, the positioning pin 22 contacts the nut under the drive of the positioning pin lifting cylinder 11, and the magnetic grid ruler 2 detects the actual displacement of the positioning pin 22 and obtains the nut position information.

[0055] Data processing and judgment: The main controller 1 receives the position signal from the magnetic scale 2 and the thickness signal from the resistance scale 3, and performs cross-verification:

[0056] If the displacement of the positioning pin 22 detected by the magnetic scale 2 exceeds the set tolerance range, it is determined that the nut is missing or installed in reverse (error prevention and reverse detection).

[0057] If the upper electrode's descent position detected by the resistance ruler 3 exceeds the set tolerance range, it is determined that the nuts are stacked (anti-overlap detection).

[0058] Execution and Alarm: If the detection result is normal, the main controller 1 controls the pneumatic solenoid valve 6 to drive the lower electrode cylinder 7 and the upper electrode pressurizing cylinder 8 to continue the welding action; if an abnormality is detected, the main controller 1 immediately controls the execution module to stop the welding action, and at the same time activates the audible and visual alarm 4 to issue an alarm signal, and displays the specific alarm code through the industrial HMI5, so that the operator can handle it in time.

[0059] This device achieves high-precision detection to prevent errors, reversals, and overlaps during nut welding through the collaborative work of multiple components, effectively improving welding quality and production efficiency, and is suitable for widespread application in automated welding production lines.

[0060] In summary, this utility model has the following beneficial effects:

[0061] Dual-sensor collaborative detection: Through cross-verification of magnetic grating ruler and resistance ruler, a dual-redundant detection mechanism is formed, which greatly reduces the false judgment rate, which can be controlled below 0.01%.

[0062] High detection accuracy: The magnetic scale has an accuracy of 5μm, and the highest accuracy can reach 2μm when combined with the timer encoder function of the main controller; the resistance scale has an accuracy of 0.1mm after digital filtering, which can accurately identify the installation status of nuts.

[0063] Fast response speed: The device automatically matches the welding sequence, and the response time from detection to output control signal is less than 10ms, which does not affect the normal welding cycle.

[0064] Adaptable to harsh environments: The resistance ruler probe is equipped with an oil-proof silicone sleeve to adapt to lubricated environments; regular demagnetization of the magnetic scale ensures long-term detection accuracy.

[0065] Comprehensive alarm functions: Multiple alarm modes are achieved through audible and visual alarms and industrial HMI, which can display specific alarm information such as no welded workpiece, workpiece exceeding positive tolerance, and workpiece exceeding negative tolerance, facilitating quick troubleshooting.

[0066] The technical solutions provided by the embodiments of this utility model have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the embodiments of this utility model. The description of the above embodiments is only for helping to understand the principles of the embodiments of this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the embodiments of this utility model. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A nut welding error prevention detection device, characterized in that: It includes a main controller, a position detection component, a thickness detection component, an alarm module, a human-machine interaction module, and an execution module; the position detection component and the thickness detection component are both electrically connected to the main controller, and the main controller is electrically connected to the alarm module, the human-machine interaction module, and the execution module respectively; the position detection component includes a magnetic scale, and the thickness detection component includes a resistance scale.

2. The nut welding error prevention detection device according to claim 1, characterized in that: The magnetic scale includes a magnetic scale head and a positioning pin. The positioning pin is connected to the magnetic scale head through a positioning pin connecting rod. The magnetic scale has an accuracy of 5μm and outputs 50 pulses per millimeter.

3. The nut welding error prevention detection device according to claim 1, characterized in that: The accuracy of the resistance ruler is ±0.05%, and the total stroke is 175mm.

4. The nut welding error prevention detection device according to claim 1, characterized in that: The main controller uses the GD32F450 chip; the main controller is equipped with a timer encoder interface and an ADC sampling interface.

5. The nut welding error prevention detection device according to claim 1, characterized in that: The alarm module is an audible and visual alarm.

6. The nut welding error prevention detection device according to claim 1, characterized in that: The execution module includes a pneumatic solenoid valve; the pneumatic solenoid valve is connected to a lower electrode cylinder and an upper electrode pressurizing cylinder respectively.

7. The nut welding error prevention detection device according to claim 1, characterized in that: The human-machine interface module is an industrial HMI and is electrically connected to the main controller.

8. The nut welding error prevention detection device according to claim 1, characterized in that: The magnetic scale is model MHO-H200.

9. The nut welding error prevention detection device according to claim 1, characterized in that: The resistance ruler is model LWF-175, and the probe of the resistance ruler is equipped with an oil-proof silicone sleeve.

10. A nut welding error prevention detection device according to claim 1, characterized in that: It also includes an electrode grip and an electrode cooling water jacket. The diameter and length of the electrode grip can be customized, and the electrode cooling water jacket is installed in conjunction with the electrode grip.

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