A multi-modal integrated online detection device for overhead conductor aluminum pole production

Abstract

This utility model discloses a multimodal integrated online inspection device for the production of aluminum rods for overhead conductors, including a lower housing and an upper housing. The lower housing and the upper housing are connected on one side by a hinge. A meter-counting guide assembly and a first transparent protective partition are fixedly installed on the top wall inside the upper housing along the direction of the aluminum rod. A first labyrinth-type aperture channel, an eddy current detection mechanism, a second transparent protective partition, a multi-angle industrial camera array, a shadowless light source, a first marking and coding mechanism, and a second labyrinth-type aperture channel are fixedly installed inside the lower housing. The first and second transparent protective partitions are correspondingly arranged to form a transparent protective partition with an aluminum rod channel in the middle. The meter-counting guide assembly includes a front meter-counting guide wheel and a rear meter-counting guide wheel. The eddy current detection mechanism is located between the front meter-counting guide wheel and the rear meter-counting guide wheel. It has the advantages of comprehensive detection methods and the ability to achieve full online inspection.

Description

Technical Field

[0001] This utility model relates to the technical field of aluminum rod testing equipment, and in particular to a multimodal integrated online testing device for the production of aluminum rods for overhead conductors. Background Technology

[0002] Aluminum rods (or aluminum rod blanks) for overhead conductors are the main raw material for manufacturing aluminum conductors. During the continuous casting and rolling process of aluminum rods, their surface quality, internal defects, and dimensional accuracy directly affect the conductivity and mechanical strength of the final conductor. Traditional quality inspection methods mainly rely on manual offline sampling or single-function online inspection equipment, which have several shortcomings: first, low inspection efficiency, making it impossible to achieve full inspection; second, limited inspection modes, making it difficult to simultaneously detect multiple defects such as surface scratches, cracks, internal porosity, and inclusions; and third, scattered inspection data, making it difficult to form a unified quality traceability system. Furthermore, the aluminum rod production site presents harsh environments such as high temperatures, dust, and vibration, placing high demands on the reliability and protective capabilities of the inspection equipment.

[0003] This application provides a multi-modal integrated online inspection device for the production of aluminum poles for overhead conductors, which is used to solve the above-mentioned problems. Summary of the Invention

[0004] The main purpose of this utility model is to solve the problems of existing aluminum rod detection methods being singular, inefficient, and unable to perform full online inspection.

[0005] This utility model provides a multi-modal integrated online inspection device for the production of aluminum poles for overhead conductors. The multi-modal integrated online inspection device for the production of aluminum poles for overhead conductors includes:

[0006] The equipment comprises a lower housing and an upper housing, connected on one side by a hinge. When the lower and upper housings are joined, an aluminum rod channel is provided. A metering guide assembly and a first transparent protective partition are fixedly installed on the top wall inside the upper housing along the aluminum rod's path. The lower housing contains a first labyrinth-style aperture channel, an eddy current detection mechanism, a second transparent protective partition, a multi-angle industrial camera array, a shadowless light source, a first marking / coding mechanism, and a second labyrinth-style aperture channel. The first and second transparent protective partitions are correspondingly arranged to form a transparent protective partition with the aluminum rod channel in the middle. The metering guide assembly includes a front metering guide wheel and a rear metering guide wheel, with the eddy current detection mechanism positioned between them.

[0007] Optionally, support rollers are also installed between the various components inside the lower housing of the device.

[0008] Optionally, the labyrinthine aperture channel is composed of multiple annular baffles arranged at intervals along the axial direction, the inner diameter of which is slightly larger than the diameter of the aluminum rod.

[0009] Optionally, the first and second transparent protective partitions are heat-resistant quartz glass plates.

[0010] Optionally, the eddy current detection mechanism includes a rotary drive mechanism, a detection body, and a rotary support mechanism. The two sides of the detection body are rotatably connected to the rotary support mechanism via bearings. The middle section of the detection body is provided with a toothed groove, which cooperates with the rotary drive mechanism.

[0011] Optionally, the rotary drive mechanism includes a support frame, a drive gear is rotatably connected to the top of the support frame, and a drive motor is fixedly installed on the side wall of the support frame, the drive motor being used to drive the drive gear.

[0012] Optionally, the detection body is a hollow cylinder, and the detection body has at least three radial mounting holes pointing to the center. Each radial mounting hole is provided with a micro-stiffness compression spring and a high-temperature resistant ceramic rolling element. The opening size of the mounting hole is smaller than the diameter of the ceramic rolling element to form an anti-detachment opening. The hollow cylinder is also provided with an eddy current detection probe mounting hole, and an eddy current detection probe is fixedly installed in the eddy current detection probe mounting hole.

[0013] Optionally, the multi-angle industrial camera array includes at least four high-speed industrial cameras, evenly distributed around the axis of the aluminum rod.

[0014] Optionally, both the front metering guide wheel and the rear metering guide wheel are equipped with photoelectric encoder rollers, and the outer circumferential surface of the photoelectric encoder rollers is provided with a wear-resistant rubber layer.

[0015] Optionally, the first marking and coding mechanism includes an annular coding structure and a coding support frame. The annular coding structure is fixedly installed on the coding support frame. The annular coding structure has several coding nozzles on the side near the aluminum rod. Each coding nozzle is connected to the coding liquid storage mechanism through a pipe. Each coding pipe is equipped with a coding valve, and the coding valve is linked to the encoder.

[0016] This invention integrates multiple functional modules such as meter counting, eddy current detection, visual inspection, and inkjet marking, enabling comprehensive one-time inspection of surface cracks, internal defects, and dimensions of aluminum rods, significantly improving inspection efficiency and reliability. Through a labyrinthine aperture channel and transparent protective partition design, dust, high temperatures, and stray light from the production site are effectively isolated, ensuring the long-term stable operation of optical and electromagnetic detection components. A rotating eddy current detection body combined with spring-loaded floating rollers ensures a constant distance between the probe and the aluminum rod. A circumferentially distributed multi-camera array, combined with a shadowless light source, achieves blind-spot-free imaging of surface defects. The meter encoder and inkjet marking mechanism are directly linked, enabling real-time and accurate marking of defect locations, facilitating quality traceability and cutting in subsequent processes. The upper and lower housings feature a hinged opening design, facilitating daily cleaning, calibration, and component replacement. Attached Figure Description

[0017] Figure 1 This is a cross-sectional view of the upper and lower housings of the device of this utility model when they are closed.

[0018] Figure 2 This is a front view of the upper and lower housings of the device of this utility model when they are closed.

[0019] Figure 3 This is a rear view of the device with the upper and lower housings of this utility model closed. Detailed Implementation

[0020] This utility model provides a multimodal integrated online inspection device for the production of aluminum poles for overhead conductors. The device includes a lower housing and an upper housing, connected on one side by a hinge. When the lower and upper housings are closed, an aluminum pole channel is provided. A meter-counting guide assembly, a first transparent protective partition, and a first marking / coding mechanism are fixedly installed on the top wall of the upper housing along the aluminum pole routing direction. The lower housing is also fixedly equipped with... The device includes a first labyrinth-style aperture channel, an eddy current detection mechanism, a second transparent protective partition, a multi-angle industrial camera array, a shadowless light source, and a second labyrinth-style aperture channel. The first and second transparent protective partitions are correspondingly arranged to form a transparent protective partition with an aluminum rod channel in the middle. The metering guide assembly includes a front metering guide wheel and a rear metering guide wheel, and the eddy current detection mechanism is located between the front and rear metering guide wheels. The main purpose of this utility model is to solve the problems of the existing technology, such as the single aluminum rod detection method, low efficiency, and inability to perform online full inspection.

[0021] The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" or "having" and any variations thereof are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0022] Example This utility model provides a multi-modal integrated online inspection device for the production of aluminum poles for overhead conductors. The multi-modal integrated online inspection device for the production of aluminum poles for overhead conductors includes: The device consists of a lower housing 2 and an upper housing 1. The lower housing 2 and the upper housing 1 are connected on one side by a hinge 15, allowing the upper housing to be opened like a lid for easy internal maintenance. When the upper housing 1 and the lower housing 2 are closed, a through-channel for aluminum rods is formed, allowing continuously produced aluminum rods to pass horizontally through the entire device. A buckle 14 is also provided to secure the closed upper and lower housings. A transverse guide roller 11 and a longitudinal guide roller 13 are provided at the aluminum rod inlet to guide the aluminum rods.

[0023] Specifically, on the top wall inside the upper housing 1 of the equipment, along the direction of travel of the aluminum rod (from front to back), a meter-counting guide assembly and a first transparent protective partition 6 are fixedly installed in sequence. The meter-counting guide assembly includes a front meter-counting guide wheel 3 and a rear meter-counting guide wheel 5, which press against the upper surface of the aluminum rod, serving to guide and measure its length. Both the front meter-counting guide wheel 3 and the rear meter-counting guide wheel 5 integrate photoelectric encoder rollers, with a wear-resistant rubber layer covering their outer circumference to increase friction and protect the surface of the aluminum rod. The combined signals from the two encoders can accurately calculate the length the aluminum rod has traversed and determine if slippage has occurred.

[0024] Inside the lower housing 2 of the equipment, along the direction of travel of the aluminum rod, are sequentially and fixedly installed a first labyrinth-type aperture channel 8, an eddy current detection mechanism 4, a second transparent protective partition 7, a multi-angle industrial camera array 16, a shadowless light source 9, a first marking and coding mechanism 10, and a second labyrinth-type aperture channel. The first labyrinth-type aperture channel 8 and the second labyrinth-type aperture channel have the same structure, both consisting of multiple annular baffles arranged at intervals along the axial direction. The inner diameter of the annular baffles is larger than the diameter of the aluminum rod, allowing the aluminum rod to pass through while effectively blocking external light and splashing dust. The eddy current detection mechanism 4 is located between the front metering guide wheel 3 and the rear metering guide wheel 5, ensuring that the aluminum rod is stably guided during detection.

[0025] The first transparent protective partition 6 (installed on the upper housing) and the second transparent protective partition 7 (installed on the lower housing) are installed correspondingly on the upper and lower sides, with a gap between them for the aluminum rod to pass through, together forming a transparent protective barrier that surrounds the aluminum rod but does not contact it. In this embodiment, a heat-resistant quartz glass plate with a thickness of 5mm is used, which can withstand high temperature radiation of over 200℃, while ensuring that the line of sight of the upper coding mechanism and the lower camera is not obstructed.

[0026] Inside the lower housing, multiple support rollers are installed between various components (such as between the eddy current detection mechanism 4 and the second transparent protective partition 7). The top of the support rollers contacts the lower surface of the aluminum rod to prevent the long-distance aluminum rod from touching or rubbing against other parts due to gravity.

[0027] The eddy current testing mechanism 4 is constructed as follows: it includes a rotary drive mechanism, a testing body, and two rotary support mechanisms (one on the left and one on the right). The testing body is a hollow cylinder, with its left and right sides rotatably connected to the rotary support mechanisms via bearings. Gear grooves are machined on the outer wall of the middle section of the testing body. The rotary drive mechanism includes a support frame, with a drive gear mounted on the top of the support frame via a rotating shaft. A drive motor is fixed to the side wall of the support frame, and the output shaft of the drive motor is connected to the drive gear. The drive gear meshes with the gear grooves on the testing body, thereby driving the entire testing body to rotate at high speed around the aluminum rod.

[0028] Three radial mounting holes, pointing towards the center, are evenly distributed along the circumference of the cylindrical wall of the detection body. Each radial mounting hole contains, from the outside in, a micro-stiffness compression spring and a high-temperature resistant ceramic rolling element. The opening of the mounting hole is machined into a tapered structure, with a diameter slightly smaller than that of the ceramic rolling element to prevent it from detaching. Thus, under the thrust of the spring, the ceramic rolling element remains firmly attached to the surface of the aluminum rod, allowing the detection body to automatically center and maintain stability during rotation. Simultaneously, eddy current detection probe mounting holes are also provided at one or more radial positions on the detection body, with eddy current detection probes fixedly installed within them. The tip of the probe is flush with or slightly lower than the top of the ceramic rolling element, ensuring a constant lift-off distance between the probe and the aluminum rod surface. When the detection body rotates, the eddy current detection probe can continuously scan the 360° circumference of the aluminum rod surface and near the surface.

[0029] The multi-angle industrial camera array consists of several high-speed industrial cameras, evenly spaced at 90° intervals around the axis of the aluminum rod. All cameras face the surface of the aluminum rod. A ring-shaped shadowless light source mounted inside the cameras provides uniform, shadowless illumination of the aluminum rod surface. The camera array can simultaneously capture images of all four sides of the aluminum rod; after image stitching, a high-resolution image of the entire cylindrical surface is obtained, used to identify surface defects such as scratches, dents, cracks, and oxide scale.

[0030] The first marking and coding mechanism includes a ring-shaped coding structure and a coding support frame. The ring-shaped coding structure is fixedly mounted on the coding support frame and fits around the aluminum rod. Multiple coding nozzles are evenly distributed on the inner side of the ring-shaped coding structure near the aluminum rod. Each coding nozzle is connected to an external coding liquid storage mechanism (such as an ink cartridge) via an independent pipe, and each pipe is equipped with an electromagnetic coding valve. These electromagnetic coding valves are electrically connected to the output of the controller, while the input of the controller is linked to the photoelectric encoder signals in the front metering guide wheel 3 and the rear metering guide wheel 5. When the eddy current detection mechanism 4 or the vision inspection system determines that there is an excessive defect at a certain point on the aluminum rod, the controller, based on the real-time accumulated length position of the encoder, precisely controls the corresponding angle and position of the coding nozzle to open when the defective part reaches below the ring-shaped coding mechanism, spraying a conspicuous mark (such as a color mark, number, or QR code) onto the surface of the aluminum rod for subsequent identification and removal.

[0031] Brief description of working principle: During the continuous production of aluminum rods (12 sections), the aluminum rods sequentially pass through the first labyrinth-style aperture channel, the eddy current detection mechanism, below the second transparent protective partition, between the multi-angle industrial camera array and the shadowless light source, and back to the second labyrinth-style aperture channel. Simultaneously, the front and rear metering guide wheels of the upper housing press against the upper surface of the aluminum rod. During operation, the eddy current detection probe rotates and scans to detect internal or subsurface defects; the vision system captures surface images to detect external defects; the metering system provides precise position coordinates; and finally, a marking mechanism marks the defects. All data can be uploaded to the central control system, enabling digital and intelligent management of the aluminum rod quality.

[0032] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A multi-modal integrated online inspection device for overhead conductor aluminum pole production, comprising a lower part of the device box and an upper part of the device box, characterized in that, The lower housing and the upper housing of the equipment are connected by a hinge on one side. When the lower housing and the upper housing are closed, an aluminum rod channel is left. A meter-counting guide assembly and a first transparent protective partition are fixedly installed on the top wall inside the upper housing along the direction of the aluminum rod. A first labyrinth-type aperture channel, an eddy current detection mechanism, a second transparent protective partition, a multi-angle industrial camera array, a shadowless light source, a first marking and coding mechanism, and a second labyrinth-type aperture channel are fixedly installed inside the lower housing. The first transparent protective partition and the second transparent protective partition are correspondingly arranged to form a transparent protective partition with an aluminum rod channel in the middle. The meter-counting guide assembly includes a front meter-counting guide wheel and a rear meter-counting guide wheel. The eddy current detection mechanism is located between the front meter-counting guide wheel and the rear meter-counting guide wheel.

2. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 1, characterized in that, Support rollers are also installed between the various components inside the lower housing of the equipment.

3. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 2, characterized in that, The labyrinthine aperture channel is composed of multiple annular baffles arranged at intervals along the axial direction, with the inner diameter of the annular baffles being slightly larger than the diameter of the aluminum rod.

4. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 3, characterized in that, The first and second transparent protective partitions are heat-resistant quartz glass plates.

5. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 4, characterized in that, The eddy current detection mechanism includes a rotary drive mechanism, a detection body, and a rotary support mechanism. The two sides of the detection body are rotatably connected to the rotary support mechanism via bearings. The middle section of the detection body is provided with a toothed groove, which cooperates with the rotary drive mechanism.

6. The multi-modal integrated online inspection device for the production of overhead conductor aluminum poles according to claim 5, characterized in that, The rotary drive mechanism includes a support frame, a drive gear is rotatably connected to the top of the support frame, and a drive motor is fixedly installed on the side wall of the support frame, the drive motor being used to drive the drive gear.

7. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 6, characterized in that, The detection body is a hollow cylinder, and at least three radial mounting holes pointing to the center are provided on the detection body. Each radial mounting hole is provided with a micro-stiffness compression spring and a high-temperature resistant ceramic rolling element. The opening size of the mounting hole is smaller than the diameter of the ceramic rolling element to form an anti-detachment opening. The hollow cylinder is also provided with an eddy current detection probe mounting hole, and an eddy current detection probe is fixedly installed in the eddy current detection probe mounting hole.

8. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 7, characterized in that, The multi-angle industrial camera array includes at least four high-speed industrial cameras, evenly distributed around the axis of the aluminum rod.

9. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 8, characterized in that, Both the front metering guide wheel and the rear metering guide wheel are equipped with photoelectric encoder rollers, and the outer circumferential surface of the photoelectric encoder rollers is provided with a wear-resistant rubber layer.

10. The multi-modal integrated online inspection device for overhead conductor aluminum pole production according to claim 9, characterized in that, The first marking and coding mechanism includes an annular coding structure and a coding support frame. The annular coding structure is fixedly installed on the coding support frame. Several coding nozzles are provided on the side of the annular coding structure near the aluminum rod. Each coding nozzle is connected to the coding liquid storage mechanism through a pipe. Each coding pipe is equipped with a coding valve. The coding valve is linked to the encoder.

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