Penetration flaw detection defect observation device

Abstract

The utility model provides a defect observation device for penetrant flaw detection. The defect observation device comprises a magnetic mark generation mechanism, an image mechanism and a man-machine interaction mechanism, the magnetic field on the surface of the workpiece is effectively applied through cooperation of the magnetic pole piece and the electromagnetic yoke, magnetic lines escape from the surface of the workpiece at the surface defect position of the workpiece to form a leakage magnetic field, and magnetic powder applied to the surface of the workpiece can be adsorbed to form aggregation magnetic marks due to existence of the magnetic pole. Meanwhile, due to the multi-shaft driving structure of the magnetic mark generating mechanism, comprehensive spraying of magnetic powder on the surface of the workpiece is achieved, it is ensured that defects are clearly shown, and the detection accuracy is improved. And secondly, the image mechanism adopts four cameras which are arranged at an included angle of 90 degrees, so that all-directional coverage on the surface of the workpiece is realized, and the defect identification capability and the detection precision are effectively improved in combination with processing of the image processing unit on the images shot by the cameras. And thirdly, the man-machine interaction mechanism is integrated with a touch display screen and a processor, so that the operation convenience and the data tracing capability are improved.

Description

Technical Field

[0001] This utility model relates to the field of penetrant testing technology, specifically to a penetrant testing defect observation device. Background Technology

[0002] Penetrant testing is a non-destructive testing method widely used in industrial manufacturing and quality inspection. It is primarily used to detect minute defects such as cracks, pores, and inclusions on the surface of materials or workpieces. This technique typically involves penetrating the defect with a penetrant, followed by the use of a developer or magnetic powder to reveal the defect area, facilitating observation and evaluation. In industries such as aerospace, automotive manufacturing, shipbuilding, petrochemicals, and railway transportation, penetrant testing plays a crucial role in improving product quality and ensuring equipment safety.

[0003] Traditional penetrant testing methods rely heavily on manual operation, such as manually applying penetrant, applying magnetic powder, and observing defects using ultraviolet lamps. This approach suffers from several drawbacks: low efficiency, especially in mass production where manual inspection struggles to meet the demands for rapid, high-precision quality control; reliance on operator experience, with differing judgment criteria among personnel affecting consistency; poor stability due to operator fatigue during extended operation, potentially leading to misjudgments or missed defects; and difficulty in data storage and traceability, as traditional methods primarily depend on manual observation and cannot create a visualized defect database, hindering subsequent analysis and quality improvement.

[0004] To address these issues, automated and intelligent flaw detection equipment has been gradually introduced into the market, such as using camera technology to assist in inspection and employing robots to perform magnetic powder spraying. However, existing automated penetrant testing equipment still has the following shortcomings: the magnetic powder application method is not precise enough, which easily leads to uneven magnetic powder distribution, affecting the accuracy of defect detection; and the image processing capability is limited, and the ability to identify and analyze minute defects still needs to be improved. Utility Model Content

[0005] To address the shortcomings of existing technologies, this invention provides a penetrant testing defect observation device, which effectively improves upon the deficiencies of some existing penetrant testing defect observation devices and enhances detection accuracy and automation.

[0006] A penetrant testing defect observation device includes a frame. A magnetic trace generation mechanism, an imaging mechanism, and a human-machine interface mechanism are mounted on top of the frame. The magnetic trace generation mechanism includes multiple support columns mounted on the top of the frame, evenly distributed on both sides of the frame. A horizontal beam is mounted above each of the support columns on both sides. A transverse beam is slidably arranged between two horizontal beams. A first drive unit is mounted on one of the horizontal beams to drive the transverse beam to slide relative to the horizontal beam. A sliding seat is mounted on the transverse beam, and a second drive unit is mounted on the transverse beam, connected to the sliding seat. A nozzle is mounted on the sliding seat, and the nozzle is connected to a magnetic powder chamber via a flexible hose. The support columns on both sides are equipped with... The system comprises a pair of opposing telescopic units. Each telescopic unit has a magnetic pole at its output end, an electromagnetic yoke at the end of the magnetic pole away from the telescopic unit, and a recessed groove at the end of the electromagnetic yoke away from the magnetic pole. A rotary motor is located in the recessed groove, and a fastening component is connected to the output end of the rotary motor. The fastening component is used to fasten a workpiece. The imaging mechanism includes multiple cameras and an image processing unit connected to the cameras. The camera system comprises four cameras, evenly distributed on the support columns on both sides, with each pair of cameras positioned at a 90° angle. The human-computer interaction mechanism includes a display screen and a processor connected to the display screen. The processor is connected to the magnetic trace generation mechanism and the imaging mechanism.

[0007] Preferably, the image processing unit includes an image enhancement module, an image filtering module, and an edge detection module.

[0008] Preferably, the fastening member includes a mounting base connected to the output end of the rotary motor, and a plurality of telescopic rods are provided at the end of the mounting base away from the rotary motor. The ends of the telescopic rods are provided with compression pads, and telescopic springs are sleeved on the outer sides of the telescopic rods.

[0009] Preferably, the first drive unit includes a first stepper motor disposed at one end of the horizontal beam, the output end of the first stepper motor is connected to a first ball screw disposed inside the horizontal beam, a slider is slidably disposed on the horizontal beam, the slider is connected to the first ball screw, the end of the slider is connected to one end of the transverse beam, and the other end of the transverse beam is slidably connected to another horizontal beam.

[0010] Preferably, the second drive unit includes a second stepper motor disposed on the transverse beam, the output end of the second stepper motor is connected to a first ball screw disposed within the transverse beam, and a sliding seat is slidably disposed on the transverse beam, the sliding seat being connected to the second ball screw.

[0011] Preferably, a suction pump is provided inside the magnetic powder chamber, and the suction pump is connected to the hose.

[0012] Preferably, the processor is a PLC processor.

[0013] Preferably, the display screen is a touch display screen.

[0014] Compared with the prior art, the present invention has the following beneficial effects:

[0015] This invention provides a penetrant testing defect observation device, comprising a magnetic trace generation mechanism, an imaging mechanism, and a human-machine interface mechanism. The magnetic trace generation mechanism, through the cooperation of its magnetic poles and electromagnetic yoke, effectively applies a magnetic field to the workpiece surface. Consequently, magnetic lines of force escape from the workpiece surface at defects, forming a leakage magnetic field. The presence of magnetic poles attracts magnetic powder applied to the workpiece surface, forming an aggregated magnetic trace. Simultaneously, the multi-axis drive structure of the magnetic trace generation mechanism ensures comprehensive spraying of magnetic powder onto the workpiece surface, guaranteeing clear defect visibility and improving detection accuracy. Secondly, the imaging mechanism employs four cameras arranged at a 90° angle, achieving omnidirectional coverage of the workpiece surface. Combined with image processing by the image processing unit, this effectively enhances defect recognition and detection accuracy. Thirdly, the human-machine interface mechanism integrates a touchscreen display and processor, enabling the operator to intuitively control the equipment, adjust detection parameters, and view and store detection results in real time, improving operational convenience and data traceability. Therefore, this penetrant testing defect observation device has a high degree of automation, can adapt to workpieces of different shapes and sizes, meets the high-standard flaw detection requirements of workpieces, and improves the stability of detection and its industrial application value. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the penetrant testing defect observation device described in this utility model;

[0017] in:

[0018] 10-Support column, 20-Horizontal beam, 30-Transverse beam, 40-Sliding seat, 50-Nozzle, 60-Telescopic unit, 70-Magnetic pole piece, 80-Electromagnetic yoke, 90-Rotary motor, 11-Fasting piece, 12-Camera, 13-Display screen, 14-Processor. Detailed Implementation

[0019] The embodiments described below are merely some embodiments of this utility model, and not all embodiments. 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.

[0020] See Figure 1 This embodiment provides a penetrant testing defect observation device, which includes a frame, and a magnetic trace generation mechanism, an imaging mechanism and a human-computer interaction mechanism are arranged on the top of the frame.

[0021] The magnetic trace generation mechanism includes multiple support columns 10 disposed above the frame. The support columns 10 are evenly distributed on both sides of the frame, and a horizontal beam 20 is installed above each of the support columns 10 on both sides. A transverse beam 30 is slidably disposed between two horizontal beams 20. A first drive unit is disposed on one of the horizontal beams 20 to drive the transverse beam 30 to slide relative to the horizontal beam 20. A sliding seat 40 is disposed on the transverse beam 30, and a second drive unit is disposed on the transverse beam 30. The second drive unit is connected to the sliding seat 40. A nozzle 50 is provided on the 40, and a magnetic powder chamber is connected to the nozzle 50 via a hose. A pair of opposing telescopic units 60 are provided on the support columns 10 on both sides. A magnetic pole 70 is provided at the output end of the telescopic unit 60. An electromagnetic yoke 80 is connected to the end of the magnetic pole 70 away from the telescopic unit 60. A recessed groove is provided at the end of the electromagnetic yoke 80 away from the magnetic pole 70. A rotary motor 90 is provided at the recessed groove. A fastening member 11 is connected to the output end of the rotary motor 90. The fastening member 11 is used to fasten the workpiece.

[0022] When it is necessary to magnetize the workpiece surface, the telescopic unit 60 operates, thereby driving the fastening member 11 to clamp the workpiece. Simultaneously, the telescopic unit 60 also moves the magnetic pole member 70 closer to the workpiece, and the electromagnetic yoke 80 is energized to generate a stable magnetic field, magnetizing the workpiece surface. Next, the first drive unit drives the transverse beam 30 to slide along the horizontal beam 20, achieving lateral movement. The second drive unit drives the sliding seat 40 to move along the transverse beam 30, thereby enabling the nozzle 50 to move and adjust in both the X and Y axes, allowing for multi-directional adjustment of the nozzle 50's position. The magnetic powder chamber supplies powder to the nozzle 50 through a flexible tube, and the nozzle 50 evenly sprays magnetic powder onto the workpiece surface, ensuring complete coverage. When defects exist on the workpiece surface, magnetic lines of force dissipate at the defects, forming a leakage magnetic field. Magnetic powder accumulates at these locations, forming noticeable magnetic traces. The rotary motor 90 allows the workpiece to be rotated, enabling the spraying of magnetic powder onto different surfaces. Therefore, through the coordinated operation of the first and second drive units, the nozzle 50 can traverse the entire surface of the workpiece, whether it is a flat workpiece or a workpiece with complex geometry, such as a workpiece with height differences or a curved surface, ensuring that the entire front surface is uniformly coated with magnetic powder, avoiding missed coating due to height differences. Furthermore, the position of the nozzle 50 can be dynamically adjusted according to the contour of the workpiece based on the image captured by the imaging mechanism, allowing for precise application of magnetic powder at different heights and in different areas. This makes it suitable for workpieces of various sizes, shapes, and complex structures, improving the coverage and accuracy of magnetic powder coating. In this application,

[0023] The imaging mechanism includes multiple cameras 12 and an image processing unit connected to each camera 12. There are four cameras 12, evenly distributed on the support columns 10 on both sides, with each pair of cameras placed at a 90° angle. The human-machine interface includes a display screen 13 and a processor 14 connected to the display screen 13. The processor 14 is connected to the magnetic trace generation mechanism and the imaging mechanism. Preferably, the image processing unit includes an image enhancement module, an image filtering module, and an edge detection module. The four cameras 12 of the imaging mechanism capture images of the workpiece surface from different angles, and the image processing unit performs image enhancement, filtering, and edge detection to highlight magnetic trace features and improve the accuracy of defect identification. Finally, the processor 14 displays the detection results through the human-machine interface, allowing the operator to view and adjust parameters in real time, improving the convenience and accuracy of the detection.

[0024] Preferably, the fastening element 11 includes a mounting base connected to the output end of the rotary motor 90. Multiple telescopic rods are provided at the end of the mounting base away from the rotary motor 90. Each telescopic rod has a compression pad at its end and a telescopic spring sleeved on its outer side. This fastening element 11 is designed to adapt to workpieces of various shapes, achieving stable clamping. When the telescopic unit 60 operates, the mounting base drives the multiple telescopic rods to move synchronously. The compression pads at the ends of the telescopic rods can adaptively adjust according to the shape of the workpiece, ensuring that workpieces of different sizes and shapes can be securely clamped. The telescopic springs on the outer side of the telescopic rods provide appropriate elasticity, preventing excessively tight or loose clamping, improving clamping stability and adaptability, and also enabling the telescopic rods to return to their original position. Simultaneously, this fastening element 11 effectively reduces the risk of workpiece deformation due to excessive clamping force, ensuring the stability of detection accuracy.

[0025] Preferably, the first drive unit includes a first stepper motor disposed at one end of the horizontal beam 20. The output end of the first stepper motor is connected to a first ball screw disposed within the horizontal beam 20. A slider is slidably disposed on the horizontal beam 20. The slider is connected to the first ball screw, and its end is connected to one end of the transverse beam 30. The other end of the transverse beam 30 is slidably connected to another horizontal beam 20. The first drive unit drives the first ball screw to rotate via the first stepper motor, thereby causing the slider to move along the horizontal beam 20, which in turn pushes the transverse beam 30 to slide relative to the horizontal beam 20, achieving precise movement of the magnetic trace generation mechanism in the X-axis direction. This design ensures that the nozzle 50 can be precisely adjusted along the X-axis direction, making the magnetic powder spraying position controllable, ensuring that the magnetic powder can uniformly cover the workpiece surface, and improving the accuracy of defect detection.

[0026] Preferably, the second drive unit includes a second stepper motor mounted on the transverse beam 30. The output end of the second stepper motor is connected to a first ball screw mounted within the transverse beam 30. A sliding seat 40 is slidably mounted on the transverse beam 30 and connected to the second ball screw. The second drive unit drives the ball screw to rotate via the second stepper motor, thereby moving the sliding seat 40 along the transverse beam 30, achieving precise adjustment of the nozzle 50 in the Y-axis direction. This design ensures that the nozzle 50 can move freely in both directions (X-axis and Y-axis), allowing the magnetic powder to fully cover the workpiece surface, improving the imaging quality of magnetic traces and the accuracy of defect detection.

[0027] Preferably, a suction pump is installed inside the magnetic powder chamber, and the suction pump is connected to the hose. The suction pump inside the magnetic powder chamber provides a stable and controllable flow rate of magnetic powder to the nozzle 50 through the hose, thereby ensuring that the magnetic powder can be sprayed evenly on the surface of the workpiece.

[0028] Preferably, the processor 14 is a PLC processor 14 with a built-in known program. Preferably, the display screen 13 is a touch display screen 13. The touch display screen 13 serves as a human-machine interface, allowing the operator to intuitively set parameters, monitor the detection process, and view the detection results. Furthermore, by connecting to the PLC processor 14, it can store data and perform backtracking, improving operational convenience and detection efficiency.

[0029] This invention provides a penetrant testing defect observation device, comprising a magnetic trace generation mechanism, an imaging mechanism, and a human-machine interface mechanism. The magnetic trace generation mechanism, through the cooperation of the magnetic pole component 70 and the electromagnetic yoke 80, effectively applies a magnetic field to the workpiece surface. Consequently, magnetic lines of force escape from the surface defects, forming a leakage magnetic field. The presence of the magnetic pole attracts the magnetic powder applied to the workpiece surface, forming an aggregated magnetic trace. Simultaneously, the multi-axis drive structure of the magnetic trace generation mechanism achieves comprehensive spraying of magnetic powder onto the workpiece surface, ensuring clear defect visibility and improving detection accuracy. Secondly, the imaging mechanism employs four cameras 12 arranged at a 90° angle, achieving omnidirectional coverage of the workpiece surface. Combined with the image processing unit's processing of the images captured by the cameras 12, it effectively enhances defect recognition capability and detection accuracy. Thirdly, the human-machine interface mechanism integrates a touch screen display 13 and a processor 14, enabling the operator to intuitively control the equipment, adjust detection parameters, and view and store detection results in real time, improving operational convenience and data traceability. Therefore, this penetrant testing defect observation device has a high degree of automation, can adapt to workpieces of different shapes and sizes, meets the high-standard flaw detection requirements of workpieces, and improves the stability of detection and its industrial application value.

[0030] The above-disclosed embodiments are merely some preferred embodiments of the present utility model, and should not be construed as limiting the scope of the present utility model. Therefore, any equivalent changes made in accordance with the scope of the present utility model patent application shall still fall within the scope of the present utility model.

Claims

1. A penetrant testing defect observation device, comprising a frame, characterized in that: A magnetic trace generation mechanism, an imaging mechanism, and a human-computer interaction mechanism are installed on the top of the rack. The magnetic trace generation mechanism includes multiple support columns disposed above the frame, the support columns being evenly distributed on both sides of the frame, and a horizontal beam being installed above each of the support columns on both sides. A transverse beam is slidably disposed between the two horizontal beams. A first drive unit is disposed on one of the horizontal beams to drive the transverse beam to slide relative to the horizontal beam. A sliding seat is disposed on the transverse beam, and a second drive unit is disposed on the transverse beam. The second drive unit is connected to the sliding seat. A nozzle is disposed on the sliding seat, and the nozzle is connected to a magnetic powder chamber via a hose. A pair of opposing telescopic units are disposed on the support columns on both sides. A magnetic pole is disposed at the output end of the telescopic unit. An electromagnetic yoke is disposed at the end of the magnetic pole away from the telescopic unit. A recessed groove is disposed at the end of the electromagnetic yoke away from the magnetic pole. A rotary motor is disposed at the recessed groove, and a fastening component is connected to the output end of the rotary motor. The fastening component is used to fasten the workpiece. The imaging mechanism includes multiple cameras and an image processing unit connected to the cameras. The cameras include four cameras, which are evenly arranged on the support columns on both sides, with each pair of cameras placed at a 90° angle. The human-computer interaction mechanism includes a display screen and a processor connected to the display screen. The processor is connected to the magnetic trace generation mechanism and the imaging mechanism.

2. The penetrant testing defect observation device as described in claim 1, characterized in that, The image processing unit includes an image enhancement module, an image filtering module, and an edge detection module.

3. The penetrant testing defect observation device as described in claim 1, characterized in that, The fastening component includes a mounting base connected to the output end of the rotary motor. A plurality of telescopic rods are provided at the end of the mounting base away from the rotary motor. A compression pad is provided at the end of each telescopic rod, and a telescopic spring is sleeved on the outer side of each telescopic rod.

4. The penetrant testing defect observation device as described in claim 1, characterized in that, The first drive unit includes a first stepper motor disposed at one end of the horizontal beam. The output end of the first stepper motor is connected to a first ball screw disposed inside the horizontal beam. A slider is slidably disposed on the horizontal beam. The slider is connected to the first ball screw, and the end of the slider is connected to one end of the transverse beam. The other end of the transverse beam is slidably connected to another horizontal beam.

5. The penetrant testing defect observation device as described in claim 1, characterized in that, The second drive unit includes a second stepper motor disposed on the transverse beam. The output end of the second stepper motor is connected to a second ball screw disposed inside the transverse beam. A sliding seat is slidably disposed on the transverse beam, and the sliding seat is connected to the second ball screw.

6. The penetrant testing defect observation device as described in claim 1, characterized in that, A suction pump is installed inside the magnetic powder chamber, and the suction pump is connected to the hose.

7. The penetrant testing defect observation device as described in claim 1, characterized in that, The processor is a PLC processor.

8. The penetrant testing defect observation device as described in claim 1, characterized in that, The display screen is a touch screen.

Images