Intelligent spraying device for magnetic powder detection

Abstract

The utility model relates to the technical field of intelligent spraying devices for magnetic powder detection, in particular to an intelligent spraying device for magnetic powder detection, which comprises a spraying box, a recycling box and a controller electrically connected with the spraying box and the recycling box. A spraying module, a sensing module and a clamping module are arranged in the spraying box, a recycling box is arranged at the bottom, and a recycling module is arranged in the recycling box; a communication module is arranged in the controller and used for processing data of the sensing module and driving the spraying module, the clamping module and the recycling module to work.

Description

Technical Field

[0001] This utility model relates to the technical field of intelligent spraying devices for magnetic particle detection, and in particular to an intelligent spraying device for magnetic particle detection. Background Technology

[0002] Magnetic particle testing technology is widely used in industrial non-destructive testing. Its core principle is to detect cracks by spraying a magnetic suspension onto the workpiece surface and utilizing the aggregation of magnetic particles at defects. Traditional magnetic particle spraying devices have the following problems:

[0003] 1. High dependence on manual operation: The nozzle angle and movement range need to be manually adjusted, resulting in uneven spray coverage, especially for irregularly shaped workpieces, which are prone to missed inspections;

[0004] 2. Poor stability of magnetic suspension: Magnetic powder is prone to precipitate in the storage tank, causing concentration fluctuations and affecting the clarity of defect display;

[0005] 3. Low level of intelligence: It lacks dynamic adaptation of environmental parameters (such as temperature and humidity) and spray parameters, and cannot be remotely monitored;

[0006] 4. Serious waste of resources: The lack of an efficient recycling system results in low utilization of the magnetic suspension, increasing testing costs.

[0007] In existing technologies, although some devices have introduced motors to drive the nozzle movement, they lack multi-dimensional coordinated control (such as the linkage adjustment of pitch angle and horizontal displacement), and have not solved key issues such as magnetic suspension sedimentation and closed-loop recovery. Utility Model Content

[0008] To overcome the shortcomings of existing methods, this invention provides an intelligent spraying device for magnetic particle detection.

[0009] The technical solution adopted by this utility model to solve its technical problem is: an intelligent spraying device for magnetic particle detection, including a spraying box, a recovery box, and a controller electrically connected to them; the spraying box is equipped with a spraying module, a sensing module, and a clamping module, and the recovery box is located at the bottom, with a recovery module inside the recovery box; the controller has a built-in communication module to process data from the sensing module and drive the spraying module, clamping module, and recovery module to work; the spraying module includes a storage tank, a magnetic suspension pump, an adjustable-angle nozzle, and an anti-settling vibration component, wherein the storage tank is located on the top of the outer wall of the spraying box, and the anti-settling vibration component is located at the bottom of the storage tank, and the top is connected to the adjustable-angle nozzle inside the spraying box through the magnetic suspension pump; the sensing module includes an ultrasonic ranging sensor, a temperature and humidity sensor, and a pressure sensor. The system includes a liquid level sensor; the ultrasonic ranging sensor is located on both sides of the adjustable angle nozzle, the temperature and humidity sensor and the pressure sensor are located on the clamping module, and the liquid level sensor is located inside the recovery module; the clamping module includes an x-axis moving component, a y-axis moving component, a z-axis moving component, and a flipping gripper; the x-axis moving component is fixed to the inner wall of the spray box, and the z-axis moving component is slidably connected above it; the top of the z-axis moving component is movably connected to the flipping gripper through the y-axis moving component; the flipping gripper is equipped with a temperature and humidity sensor and has a pressure sensor inside; the recovery module includes a diversion plate, recovery holes, and a movable magnetic powder recovery box; the diversion plate is located at the bottom of the spray box, with several sets of recovery holes in the middle; the movable magnetic powder recovery box is slidably connected to the bottom of the recovery box and communicates with the inside of the spray box through the recovery holes.

[0010] According to another embodiment of the present invention, the anti-sedimentation vibration component is a vibration motor installed at the bottom of the storage tank.

[0011] According to another embodiment of the present invention, the adjustable angle nozzle is further included in that the adjustable angle nozzle is connected to the servo motor via a gear transmission mechanism, and the nozzle pitch angle adjustment range is -45° to 45°; the servo motor is electrically connected to the controller.

[0012] According to another embodiment of the present invention, the gear transmission mechanism further includes a first gear and a second gear that mesh perpendicularly with each other; the output shaft of the first gear is connected to a servo motor, and the output shaft of the second gear is connected to a rotating plate; an adjustable angle nozzle is mounted on the rotating plate.

[0013] According to another embodiment of the present invention, the adjustable angle nozzle is further comprising being connected to a storage tank via an infusion pipe, wherein a magnetic suspension pump is provided in the infusion pipe.

[0014] According to another embodiment of the present invention, the bottom of the movable magnetic powder recycling box is slidably connected to the rodless cylinder via a slider; the right side of the recycling box is provided with a hole through which the movable magnetic powder recycling box can pass; and the rodless cylinder is electrically connected to the controller.

[0015] According to another embodiment of the present invention, the magnetic suspension pump, the anti-sedimentation vibration assembly, the x-axis moving assembly, the y-axis moving assembly, the z-axis moving assembly, and the flipping gripper are electrically connected to the controller.

[0016] The beneficial effects of this utility model are: 1. Full-process automated control: Through the coordinated work of multi-axis moving components and flipping grippers, combined with the precise positioning of adjustable angle nozzles, 360° no-dead-angle spraying inspection of complex workpiece surfaces can be achieved, and the inspection efficiency is improved by more than 60% compared with traditional manual operation.

[0017] 2. Intelligent parameter adjustment system: It integrates a multi-type sensor network (ultrasound / temperature and humidity / pressure / liquid level) to monitor the spray distance (±0.5mm accuracy), environmental parameters and clamping pressure in real time. It intelligently optimizes the spray pressure and flow rate through algorithms to ensure that the uniformity of the magnetic suspension coating thickness reaches ±0.1mm.

[0018] 3. Recycling, energy saving and environmental protection: The use of vibration anti-sedimentation components (adjustable amplitude range of 0.5-3mm) combined with the diversion plate-recovery box system increases the magnetic suspension recovery rate to over 92%, reducing material consumption by 40% compared to traditional open spraying.

[0019] 4. Adaptive clamping system: The three-axis linkage mechanism (X / Y / Z axis positioning accuracy ±0.1mm) combined with pressure feedback grippers can stably clamp workpieces weighing 5kg-200kg, and the clamping force can be intelligently adjusted from 2-50N to avoid damage to the workpiece surface. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] Figure 1 This is a schematic diagram of the structure of this utility model;

[0022] Figure 2 yes Figure 1 A magnified view of part A in the image;

[0023] Figure 3 This is a front view of the multi-axis motion component;

[0024] Figure 4 This is a schematic diagram of the flipper gripper structure;

[0025] Figure 5 This is the electrical wiring diagram for this utility model.

[0026] In the diagram: 1. Spray box; 2. Recycling box; 3. Controller; 4. Spray module; 4-1. Storage tank; 4-2. Magnetic suspension pump; 4-3. Adjustable angle nozzle; 4-3-1. Gear transmission mechanism; 4-3-1-1. Gear 1; 4-3-1-2. Gear 2; 4-3-2. Servo motor; 4-3-3. Rotating plate; 4-3-4. Infusion pipe; 4-4. Anti-sedimentation vibration assembly; 5. Sensor module; 5-1. Ultrasonic wave. 5-2. Distance sensor, 5-3. Temperature and humidity sensor, 5-4. Pressure sensor, 5-5. Liquid level sensor, 6. Clamping module, 6-1. X-axis moving assembly, 6-2. Y-axis moving assembly, 6-3. Z-axis moving assembly, 6-4. Flipping gripper, 7. Recycling module, 7-1. Drain plate, 7-2. Recycling hole, 7-3. Movable magnetic powder recycling box, 7-3-1. Slider, 7-3-2. Rodless cylinder, 8. Communication module. Detailed Implementation

[0027] like Figure 1This is a schematic diagram of the structure of this utility model, an intelligent spraying device for magnetic particle detection, including a spraying box 1, a recovery box 2, and a controller 3 electrically connected to them; the spraying box 1 is equipped with a spraying module 4, a sensing module 5, and a clamping module 6, and the recovery box 2 is located at the bottom, with a recovery module 7 inside the recovery box 2; the controller 3 has a built-in communication module 8, which processes the data from the sensing module 5 and drives the spraying module 4, the clamping module 6, and the recovery module 7 to work; the spraying module 4 includes a storage tank 4-1, a magnetic suspension pump 4-2, an adjustable angle nozzle 4-3, and an anti-sedimentation vibration component 4-4, wherein the storage tank 4-1 is located on the top of the outer wall of the spraying box 1, and the bottom of its interior is equipped with the anti-sedimentation vibration component 4-4, and the top is connected to the adjustable angle nozzle 4-3 inside the spraying box 1 through the magnetic suspension pump 4-2; the sensing module 5 includes an ultrasonic ranging sensor 5-1, a temperature and humidity sensor 5-2, a pressure sensor 5-3, and a liquid level sensor 5-4; the ultrasonic ranging sensor 5-1... 1. An adjustable angle nozzle 4-3 is positioned on both sides of a clamping module 6. A temperature and humidity sensor 5-2 and a pressure sensor 5-3 are mounted on the clamping module 6, and a liquid level sensor 5-4 is mounted inside the recovery module 7. The clamping module 6 includes an x-axis moving component 6-1, a y-axis moving component 6-2, a z-axis moving component 6-3, and a flipping gripper 6-4. The x-axis moving component 6-1 is fixed to the inner wall of the spray box 1, and the z-axis moving component 6-3 is slidably connected above it. The top of the z-axis moving component 6-3 is movably connected to the flipping gripper 6-4 through the y-axis moving component 6-2. The flipping gripper 6-4 is equipped with a temperature and humidity sensor 5-2 and a pressure sensor 5-3 inside. The recovery module 7 includes a diversion plate 7-1, recovery holes 7-2, and a movable magnetic powder recovery box 7-3. The diversion plate 7-1 is positioned at the bottom of the spray box 1, with several sets of recovery holes 7-2 in the middle. The movable magnetic powder recovery box 7-3 is slidably connected to the bottom of the recovery box 2 and communicates with the inside of the spray box 1 through the recovery holes 7-2.

[0028] According to another embodiment of the present invention, the anti-sedimentation vibration component 4-4 is a vibration motor installed at the bottom of the liquid storage tank 4-1.

[0029] According to another embodiment of the present invention, the adjustable angle nozzle 4-3 is further connected to the servo motor 4-3-2 via a gear transmission mechanism 4-3-1, and the nozzle pitch angle adjustment range is -45° to 45°; the servo motor 4-3-2 is electrically connected to the controller 3.

[0030] According to another embodiment of the present invention, the gear transmission mechanism 4-3-1 further includes a gear 4-3-1-1 and a gear 4-3-1-2 that mesh perpendicularly with each other; the output shaft of the gear 4-3-1-1 is connected to the servo motor 4-3-2, and the output shaft of the gear 4-3-1-2 is connected to the rotating plate 4-3-3; an adjustable angle nozzle 4-3 is mounted on the rotating plate 4-3-3.

[0031] According to another embodiment of the present invention, the adjustable angle nozzle 4-3 is further connected to the storage tank 4-1 through the infusion pipe 4-3-4, wherein the infusion pipe 4-3-4 is provided with a magnetic suspension pump 4-2.

[0032] According to another embodiment of the present invention, the movable magnetic powder recycling box 7-3 is slidably connected to the bottom of the rodless cylinder 7-3-2 via a slider 7-3-1; the right side of the recycling box 2 is provided with a hole through which the movable magnetic powder recycling box 7-3 can pass; and the rodless cylinder 7-3-2 is electrically connected to the controller 3.

[0033] According to another embodiment of the present invention, the magnetic suspension pump 4-2, the anti-sedimentation vibration component 4-4, the x-axis moving component 6-1, the y-axis moving component 6-2, the z-axis moving component 6-3, and the flipping gripper 6-4 are electrically connected to the controller 3.

[0034] Example 1: When inspecting cylindrical workpieces, the operator sets the inspection parameters via controller 3. The clamping module 6, through the x-axis moving component 6-1, drives the z-axis moving component 6-3 to rise and fall, and the y-axis moving component 6-2 to move laterally, allowing the flipping gripper 6-4 to precisely grasp the workpiece. Pressure sensor 5-3 monitors the clamping force in real time and automatically adjusts the clamping force when a cylindrical workpiece is detected. After the spray module 4 is activated, the anti-sedimentation vibration component 4-4 keeps the magnetic suspension in the storage tank 4-1 uniformly suspended. The magnetic suspension delivery pump 4-2 delivers the liquid to the nozzle via the delivery pipe 4-3-4. After the ultrasonic ranging sensor 5-1 measures the distance to the workpiece surface, controller 3 drives the servo motor 4-3-2 to adjust the nozzle pitch angle to 30° via the gear transmission mechanism 4-3-1, ensuring the spray covers the workpiece surface. When the recovery module 7 is working, the residual spray liquid is guided by the diversion plate 7-1 and enters the movable magnetic powder recovery box 7-3 through the recovery hole 7-2. When the liquid level sensor 5-4 detects that the liquid level has reached 80%, the controller 3 activates the rodless cylinder 7-3-2 to move the recovery tank along the slide rail for replacement. Throughout the process, the temperature and humidity sensor 5-2 continuously monitors environmental parameters to ensure that the ambient humidity is maintained within the standard range of 40-60%RH.

[0035] Example 2: For the inspection of irregularly shaped workpieces, the operator can remotely set parameters through the communication module 8. When a change in the curvature of the workpiece surface is detected, the x / y / z axis components adjust the spray distance in conjunction, while the nozzle angle is automatically compensated by ±15°. After each sprayed surface is completed, the flipping gripper 6-4 rotates 90° according to a preset program to spray the next surface, achieving fully automatic continuous operation throughout the entire process.

[0036] The above description is illustrative only and not restrictive of this utility model. Those skilled in the art will understand that many modifications, variations or equivalents can be made without departing from the spirit and scope defined by the appended claims, and all such modifications, variations or equivalents will fall within the protection scope of this utility model.

Claims

1. An intelligent spraying device for magnetic particle detection, comprising a spraying box (1), a recovery box (2), and a controller (3) electrically connected thereto; the spraying box (1) is provided with a spraying module (4), a sensing module (5), and a clamping module (6), and the recovery box (2) is provided at the bottom, with a recovery module (7) provided inside the recovery box (2); the controller (3) has a built-in communication module (8) to process data from the sensing module (5) and drive the spraying module (4), the clamping module (6), and the recovery module (7) to work; the spraying module (4) includes a storage tank (4-1), a magnetic suspension pump (4-2), an adjustable angle nozzle (4-3), and an anti-sedimentation vibration assembly (4-4), wherein, The storage tank (4-1) is located on the top of the outer wall of the spray box (1), and its bottom is equipped with an anti-sedimentation vibration component (4-4). The top is connected to the adjustable angle nozzle (4-3) in the spray box (1) through a magnetic suspension pump (4-2). The sensing module (5) includes an ultrasonic ranging sensor (5-1), a temperature and humidity sensor (5-2), a pressure sensor (5-3), and a liquid level sensor (5-4). The ultrasonic ranging sensor (5-1) is located on both sides of the adjustable angle nozzle (4-3), the temperature and humidity sensor (5-2) and the pressure sensor (5-3) are located on the clamping module (6), and the liquid level sensor (5-4) is located in the recovery module (7). The clamping module (6) includes an x-axis moving component (6-1), a y-axis moving component (6-2), and a z-axis moving component (6-3). 3) and flipping gripper (6-4); the x-axis moving component (6-1) is fixed on the inner wall of the spray box (1), and the z-axis moving component (6-3) is slidably connected above it. The top of the z-axis moving component (6-3) is slidably connected to the flipping gripper (6-4) through the y-axis moving component (6-2); the flipping gripper (6-4) is provided with a temperature and humidity sensor (5-2) and a pressure sensor (5-3) inside; the recycling module (7) includes a diversion plate (7-1), a recycling hole (7-2) and a movable magnetic powder recycling box (7-3); the diversion plate (7-1) is set at the bottom of the spray box (1), and several sets of recycling holes (7-2) are provided in the middle. The movable magnetic powder recycling box (7-3) is slidably connected to the bottom of the recycling box (2) and is connected to the inside of the spray box (1) through the recycling hole (7-2).

2. The intelligent spray device for magnetic particle detection according to claim 1, characterized in that, The anti-sedimentation vibration component (4-4) is a vibration motor, which is installed at the bottom of the liquid storage tank (4-1).

3. The intelligent spray device for magnetic particle detection according to claim 1, characterized in that, The adjustable angle nozzle (4-3) is connected to the servo motor (4-3-2) through a gear transmission mechanism (4-3-1), and the nozzle pitch angle adjustment range is -45° to 45°; the servo motor (4-3-2) is electrically connected to the controller (3).

4. The intelligent spray device for magnetic particle detection according to claim 3, characterized in that, The gear transmission mechanism (4-3-1) includes a gear one (4-3-1-1) and a gear two (4-3-1-2) that mesh perpendicularly with each other; the output shaft of the gear one (4-3-1-1) is connected to the servo motor (4-3-2), and the output shaft of the gear two (4-3-1-2) is connected to the rotating plate (4-3-3); an adjustable angle nozzle (4-3) is installed on the rotating plate (4-3-3).

5. The intelligent spray device for magnetic particle detection according to claim 3, characterized in that, The adjustable angle nozzle (4-3) is connected to the storage tank (4-1) through the infusion pipe (4-3-4), and the infusion pipe (4-3-4) is equipped with a magnetic suspension pump (4-2).

6. The intelligent spraying device for magnetic particle detection according to claim 1, characterized in that, The bottom of the movable magnetic powder recycling box (7-3) is slidably connected to the rodless cylinder (7-3-2) via a slider (7-3-1); the right side of the recycling box (2) is provided with a hole through which the movable magnetic powder recycling box (7-3) can pass; the rodless cylinder (7-3-2) is electrically connected to the controller (3).

7. The intelligent spray device for magnetic particle detection according to claim 1, characterized in that, The magnetic suspension pump (4-2), the anti-sedimentation vibration assembly (4-4), the x-axis moving assembly (6-1), the y-axis moving assembly (6-2), the z-axis moving assembly (6-3), and the flipping gripper (6-4) are electrically connected to the controller (3).

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