AI intelligent multi-specification small workpiece X-ray detection device

Abstract

The utility model relates to an AI intelligence multi-specification small workpiece X -ray detection device, include: detection lead room, matrix camera module, mechanical hand moving mechanism, multi -axis manipulator, conveyer line, imager, imager support adjusting mechanism, ray machine, ray machine support adjusting mechanism, pair of radiation grating ruler, outer protection lead cover, protection lead curtain, AI control center, first is to adopt the structure light three -dimensional scanning technique to carry out three -dimensional modeling to workpiece, combines the data parameter of X -ray penetration thickness irradiation intensity, utilizes AI wisdom calculation technology to carry out intelligent analysis to the three -dimensional modeling digital data generated, and the optimal detection scheme is analyzed to intelligent calculation, completes the intelligent radiation detection of multi -specification small workpiece mixed together, and detection efficiency improves greatly, gets rid of manual operation intervention, realizes AI intelligent control, realized the important step of nondestructive testing industry to high -tech, is suitable for widely promoting.

Description

Technical Field

[0001] This utility model relates to the field of X-ray nondestructive testing of small workpieces, and in particular to an AI intelligent X-ray testing device and method for multiple specifications of small workpieces. Background Technology

[0002] X-ray inspection of small workpieces is currently a routine inspection technology, but it is insufficient for inspecting a wide variety of small workpieces with complex and varied shapes mixed together. The inspection process is cumbersome and remains in a semi-automatic state. Existing simple technologies only perform planar scanning inspection, resulting in low accuracy and insufficient inspection angles and positions, failing to meet inspection requirements. Current semi-automatic inspection technologies require confirming the specific model of each workpiece before performing targeted inspection, leading to low efficiency. Manual screening of workpieces for separate inspection further reduces efficiency when inspecting a large number of diverse workpieces mixed together. Existing barcode scanning technology can mark each workpiece with... While current technologies include barcode scanning for inspection, this requires an additional pre-barcode coding process. Some workpieces lack suitable locations for pre-barcode coding, and subsequent scanning is extremely difficult due to the diverse types and varying locations of the workpieces. Furthermore, the large variety of workpieces necessitates a vast database for comparison, resulting in low inspection efficiency. Although existing technologies have improved automation, they still struggle with the mixed inspection of numerous small workpieces of varying shapes and sizes. Pre-barcode coding is difficult, as is scanning before inspection and database comparison. Each workpiece needs to be individually screened to determine its inspection location and plan, leading to extremely low automated inspection efficiency and failing to meet current production inspection needs. Moreover, current technologies only rely on sensor-based automatic inspection, not true AI-powered intelligent inspection. Significant manual intervention is still required for workpiece screening and comparison, database entry of workpiece parameters, selection of personalized inspection locations for individual workpieces, and analysis of inspection results, all contributing to low efficiency. There is an urgent need for an AI-powered intelligent inspection device that eliminates the need for workpiece coding and scanning, capable of handling a wide variety of small workpieces of complex specifications—a highly intelligent and automated inspection device to quickly complete the inspection process. Summary of the Invention

[0003] To address the shortcomings of existing technologies and truly achieve AI-powered intelligent inspection, this patent provides an AI-powered intelligent X-ray inspection device for multi-specification small workpieces, comprising: an inspection lead room, a matrix camera module, a robotic arm moving mechanism, a multi-axis robotic arm, a conveyor line, an imager, an imager support and adjustment mechanism, an X-ray machine, an X-ray machine support and adjustment mechanism, a through-beam grating ruler, an outer protective lead cover, a protective lead curtain, and an AI control center.

[0004] A robotic arm moving mechanism is installed on the top frame of the lead testing room. Below the robotic arm moving mechanism, a multi-axis robotic arm is installed. An imager support and adjustment mechanism is installed on the front side wall in the middle of the lead testing room, with an imager installed at its front end. A X-ray machine support and adjustment mechanism is installed on the rear side wall in the middle of the lead testing room, with an X-ray machine installed at its front end. The X-ray receiving area of ​​the imager corresponds to the X-ray generating window of the X-ray machine on the same axis. A conveyor belt is installed in the middle of the lead testing room, with both ends of the conveyor belt extending out of the testing window of the lead testing room. External protective lead covers are installed on the outer sides of both ends of the testing window and in the space above the conveyor belt. A protective lead curtain is installed at the end of the lead shield. The protective lead room, the protective lead shield, and the protective lead curtain form a closed space. Multiple sets of matrix camera modules are evenly distributed in the middle of the inner side wall of the lead room, pointing towards the workpiece at the center of the conveyor line above the lead room from the side and diagonally, and scanning and modeling the workpiece. Multiple sets of matrix camera modules are evenly distributed in the middle top and bottom of the lead room, pointing towards the workpiece at the center of the conveyor line from the top and bottom, respectively, and scanning and modeling the workpiece. With the center of the conveyor line as the center point, through-beam grating rulers are symmetrically installed on the diagonal side wall inside the lead room for measuring and correcting the actual size of the workpiece. An AI control center is installed outside the lead room.

[0005] The lead testing room uses a steel frame as its skeleton, and protective lead plates are installed on the outside of the skeleton for radiation protection. The lead plates are fixed to the skeleton by welding thin steel plates on both sides with lead plates sandwiched in the middle.

[0006] The matrix camera module uses structured light 3D scanning technology to create a 3D model of the workpiece. It includes a high-definition camera, a flicker-free LED light, and a projector. The high-definition camera, flicker-free LED light, and projector are evenly and symmetrically distributed around the workpiece to be inspected, on the side walls, the roof, and the ground in the middle of the inspection room, forming a multi-dimensional central matrix module.

[0007] The conveyor system adopts a standard flexible belt conveyor system, which uses servo motors to control the transmission and precisely control the position of the conveyor.

[0008] The AI ​​control center is the core brain of this inspection device, including: industrial control computer center, automatic control module, modeling and calculation module, intelligent program calculation module, X-ray imaging processing module, and inspection image analysis module; all modules coordinate and work together to complete the entire process of intelligent X-ray inspection of the workpiece.

[0009] The robotic arm moving mechanism uses linear guide rails and sliders for guidance, and servo motors drive gear racks to move, driving the multi-axis robotic arm on the upper part of the lead room in both horizontal and vertical directions for movement and positioning.

[0010] The multi-axis robotic arm employs standard robotic arm technology, capable of retracting and flexing its gripper to grasp workpieces and moving and rotating them for scanning and inspection. It includes: a two-jaw gripper, a three-jaw gripper, a shaped workpiece gripper, a robotic arm holder, a robotic arm rear arm, a robotic arm intermediate arm, and a robotic arm pneumatic gripper conversion base. The robotic arm holder is mounted below the robotic arm's moving mechanism, containing a rotary bearing and drive motor for rotational movement. The robotic arm rear arm is connected to the robotic arm holder via a hinge and is driven by a motor for rotational bending. The robotic arm intermediate arm is connected to the robotic arm rear arm via a hinge. The robot arm is connected to the lower part of the intermediate arm via a motor, and the rear arm is connected to it via a hinge. The rear arm is also connected to the lower part of the rear arm via a motor, and a gripper conversion seat is connected to it. The rear arm contains a rotary bearing and a drive motor, which can drive the gripper conversion seat connected below to rotate. The front end of the gripper conversion seat is a convertible spherical adjustment mechanism, and a two-jaw gripper, a three-jaw gripper, and a workpiece gripper are connected to it. One set of grippers is located at the bottom, and the other two sets of grippers are evenly distributed at a certain angle on both sides. They can be automatically rotated and switched as needed.

[0011] The LED flicker-free light projector evenly illuminates the workpiece surface with a grid pattern. A high-definition camera captures images of the workpiece from various angles, and the captured data is transmitted to the AI ​​control center for 3D modeling. A through-beam grating ruler scans the workpiece to measure its actual height, and the measurement data is transmitted to the AI ​​control center for further dimensional correction of the generated 3D model, resulting in a final 1:1 model of the actual workpiece.

[0012] The middle tray and frame of the conveyor line have a hollow structure, and the conveyor belt of the conveyor line is made of transparent PVC material. The matrix camera module can scan and model the lower contour of the workpiece through the conveyor belt.

[0013] The multi-axis robot's front-end mechanical gripper is an automatically convertible, adjustable fixture, including: a two-jaw gripper, a three-jaw gripper, and a fixture for irregularly shaped workpieces. The appropriate fixture is matched according to the shape of the workpiece being inspected: long and square workpieces are matched with a two-jaw gripper, cylindrical and polygonal workpieces with a three-jaw gripper, and slender and flat workpieces with a fixture for irregularly shaped workpieces. The spherical rotating structure of the multi-axis robot's front-end mechanical gripper rotates the corresponding fixture to the lowest working position according to the workpiece shape. If the shape of the workpiece to be inspected does not match the fixture, the robot's gripper conversion seat automatically rotates and adjusts to the corresponding fixture.

[0014] The control methods of the AI ​​control center include:

[0015] As the core control center, the industrial control computer center coordinates the various modules to work together in an orderly manner, communicates with the testing personnel through the human-machine interface, and summarizes and stores various data during the testing process.

[0016] The automatic control module is the drive control center of this device. It receives overall coordinated control from the industrial control computer center and is responsible for the transmission control of all operating actions, including: the drive transmission control of the production line, the drive control of the horizontal and vertical adjustment of the multi-axis robot arm moving mechanism, the drive control of the rotation and bending of each joint of the multi-axis robot arm, and the drive control of the adjustment, conversion and workpiece gripping of the front-end pneumatic gripper.

[0017] The modeling and calculation module receives overall collaborative control from the industrial control computer center. It performs structured light 3D scanning of the workpiece from various angles through the matrix camera module, performs centralized modeling and calculation on multiple sets of scan data images, synthesizes the 3D model module of the workpiece, and then scans the workpiece to measure the actual height data through the through-beam grating ruler, performs correction, and obtains the final 1:1 3D model digital data of the actual workpiece.

[0018] The intelligent program calculation module receives overall collaborative control from the industrial control computer center. It intelligently analyzes the 3D modeling digital data generated in the modeling calculation module. By analyzing the workpiece's shape, dimensions, and specific contours, and combining this with the optimal detection image size, radiation intensity, penetration thickness, and image penetration angle provided by the X-ray imaging processing module, it intelligently calculates and analyzes the optimal detection scheme. The detection scheme includes: selection of the gripping method (three-jaw clamp for round workpieces, two-jaw clamp for square workpieces, and irregularly shaped workpiece clamp for slender and flat workpieces); and selection of the detection position based on the workpiece's shape, size, and radiation penetration thickness. The system determines the size of the imaging area, selects the optimal illumination angle and the sequence of movement steps; selects the X-ray intensity parameters based on the actual thickness and position information of the workpiece, choosing suitable X-ray tube current and voltage parameters to determine the X-ray intensity; selects the movement steps: based on the previous gripping position and the imaging detection area, it determines whether to grip a rectangular workpiece and move it parallel to complete the detection of all positions of the entire workpiece, or grip a cylindrical workpiece and rotate it sequentially to complete the detection of all positions of the entire workpiece, or grip an irregularly shaped workpiece and flip it sequentially to complete the detection of all positions of the entire workpiece. Finally, the system intelligently calculates the optimal detection scheme and sends the calculation results to the industrial control computer center.

[0019] The industrial control computer center coordinates other modules according to the optimal detection plan, executes the detection plan, drives the multi-axis robot to work, picks up the workpiece to the detection position, and performs rotational and parallel movements. At the same time, the X-ray imaging processing module is started, and the X-ray machine and imager are turned on to perform automatic X-ray detection. After the detection is completed, the X-ray is turned off and the workpiece is placed on the conveyor line and sent out of the detection lead room.

[0020] The X-ray imaging processing module receives overall collaborative control from the industrial control computer center. It transmits the X-ray intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the X-ray machine to the intelligent program calculation module. After calculating the optimal workpiece inspection plan, it turns on the X-ray machine, adjusts the input tube current and tube voltage, outputs the X-ray intensity of the execution plan, and simultaneously turns on the imager to receive X-rays passing through the workpiece for imaging inspection. It then transmits the inspection image information to the inspection image analysis module. After the inspection is completed, it turns off the X-ray machine imager according to the instructions.

[0021] The detection image analysis module receives overall collaborative control from the industrial control computer center. After receiving the detection image information, it processes the image using software. Based on the requirements for contrast, sensitivity, and clarity of the detection image, it judges whether the workpiece meets the X-ray detection qualification standard. If it meets the standard, it is marked, and the detection data is archived and saved.

[0022] One type of detection method using an AI-powered intelligent X-ray inspection device for small workpieces of various sizes:

[0023] Step 1: The workpiece to be inspected is conveyed to the conveyor line and passed through the protective lead curtain and outer protective lead cover in sequence to be positioned in the middle of the lead inspection room;

[0024] Step 2: The AI ​​control center starts working. The modeling and calculation module receives overall collaborative control from the industrial control computer center. The matrix camera module performs structured light 3D scanning of the workpiece from multiple angles, including the side, top, and bottom. The LED flicker-free light projector evenly transmits grid-like light onto the workpiece surface. The high-definition camera captures images of the workpiece from various angles. Multiple sets of scanned images are centrally modeled and calculated to synthesize a 3D model module of the workpiece. Then, the workpiece is scanned and measured using a through-beam grating ruler to obtain the actual height data, which is then corrected to obtain the final 1:1 3D model digital data that matches the actual workpiece.

[0025] Step 3: The intelligent program calculation module receives overall collaborative control from the industrial control computer center, and performs intelligent analysis on the 3D modeling digital data generated in the modeling calculation module. It analyzes the workpiece's shape structure, dimensions, and specific outline, and combines the X-ray intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the X-ray imaging processing module to perform comprehensive analysis. The intelligent calculation and analysis determine the optimal detection scheme, selects the gripping method, the detection position, the X-ray intensity parameters, and the motion steps, and sends the calculation results to the industrial control computer center.

[0026] Step 4: The industrial control computer center coordinates with the X-ray imaging processing module to turn on the X-ray machine, adjust the input tube current and voltage of the X-ray machine according to the execution plan, output the X-ray intensity of the execution plan, and simultaneously turn on the imager to receive X-rays passing through the workpiece for imaging detection.

[0027] Step 5: The industrial control computer center coordinates with the automatic control module to drive the robot arm moving mechanism according to the optimal scheme calculated by intelligent calculation. The robot arm is carried to a position directly above the workpiece. The robot arm is driven to automatically rotate and adjust the robot arm gripper conversion seat to the corresponding matching fixture. The front end gripper is extended to grab the workpiece. After the X-ray is turned on synchronously, the workpiece is driven to complete the translation, rotation or flipping movement according to the scheme. After the inspection is completed, the workpiece is returned to the conveyor line, the X-ray is turned off, and the conveyor line is driven to send the workpiece out of the inspection room.

[0028] The beneficial technical effects are as follows: This utility model solves the defects and deficiencies of the existing technology and provides an AI intelligent X-ray inspection device for multi-specification small workpieces. It fundamentally solves the problem that the existing technology cannot efficiently inspect complex X-ray inspections of small workpieces with multiple specifications mixed together. Compared with the traditional manual operation and intervention inspection, this device truly realizes AI intelligent operation and inspection throughout the entire process. It can complete the rapid inspection of various small workpieces mixed together, greatly improves the inspection efficiency, gets rid of manual operation and intervention, realizes AI intelligent control, and realizes an important step for the non-destructive testing industry to advance towards high technology. It is suitable for widespread promotion. Attached Figure Description

[0029] Figure 1 This is the front view of the device;

[0030] Figure 2 This is a side view of the device;

[0031] Figure 3 This is a top view of the device;

[0032] In the diagram: 1. Lead inspection room; 2. Matrix camera module; 3. Robotic arm moving mechanism; 4. Multi-axis robotic arm; 5. Conveyor assembly line; 6. Imager; 7. Imager support and adjustment mechanism; 8. X-ray machine; 9. X-ray machine support and adjustment mechanism; 10. Through-beam grating ruler; 11. Outer protective lead cover; 12. Protective lead curtain; 13. AI control center; 14. Workpiece; 21. High-definition camera; 22. LED flicker-free light; 23. Projector; 41. Two-jaw gripper; 42. Three-jaw gripper; 43. Irregular workpiece gripper; 44. Mechanical handpiece holder; 45. Robotic arm rear arm; 46. Robotic arm intermediate arm; 47. Robotic arm rear arm; 48. Robotic gripper conversion seat; 51. Conveyor belt. Detailed Implementation

[0033] The preferred embodiments of this patent are described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely for explaining the technical principles of this patent and are not intended to limit the scope of protection of this patent.

[0034] An AI-powered intelligent X-ray inspection device for small workpieces of various sizes includes: a lead inspection room 1, a matrix camera module 2, a robotic arm moving mechanism 3, a multi-axis robotic arm 4, a conveyor line 5, an imager 6, an imager support and adjustment mechanism 7, an X-ray machine 8, an X-ray machine support and adjustment mechanism 9, a through-beam grating ruler 10, an outer protective lead cover 11, a protective lead curtain 12, and an AI control center 13.

[0035] A robotic arm moving mechanism 3 is installed on the top frame of the lead testing room 1. Below the robotic arm moving mechanism 3, a multi-axis robotic arm 4 is installed. An imager support and adjustment mechanism 7 is installed on the front side wall in the middle of the lead testing room 1. An imager 6 is installed at the front end of the imager support and adjustment mechanism 7 for receiving real-time X-ray imaging. A X-ray machine support and adjustment mechanism 9 is installed on the rear side wall in the middle of the lead testing room 1. A X-ray machine 8 is installed at the front end of the X-ray machine support and adjustment mechanism 9 for generating emitted X-rays for imaging detection. The X-ray receiving area of ​​the imager 6 corresponds to the X-ray generating window of the X-ray machine 8 on the same axis. A conveyor line 5 is installed at the middle ground position of the lead testing room 1. Both ends of the conveyor line 5 extend out of the testing window of the lead testing room 1. An outer protective lead cover 11 is installed on the outer side of both ends of the testing window of the lead testing room 1 and in the space above the conveyor line 5. A protective lead curtain 12 is installed at the end of the lead cover 11. The protective lead room 1, the protective lead cover 11, and the protective lead curtain 12 form a closed space to shield X-rays and avoid radiation from outdoor X-rays. Multiple sets of matrix camera modules 2 are evenly distributed in the middle of the inner side wall of the lead room 1, pointing towards the workpiece 14 at the center of the conveyor line 5 above the lead room 1 from the side and diagonally, respectively, to scan and model the workpiece 14. Multiple sets of matrix camera modules 2 are evenly distributed in the middle top and bottom of the lead room 1, pointing towards the workpiece 14 at the center of the conveyor line 5 from the top and bottom, respectively, to scan and model the workpiece 14. With the center of the conveyor line 5 as the center point, symmetrical through-beam grating rulers 10 are provided on the diagonal side wall inside the lead room 1, used to measure and correct the actual size of the workpiece 14. An AI control center 13 is installed outside the lead room 1.

[0036] The lead testing room 1 uses a steel frame as its skeleton, and protective lead plates are installed on the outside of the skeleton for radiation protection. The lead plates are fixed to the skeleton by welding thin steel plates on both sides with lead plates sandwiched in the middle.

[0037] The matrix camera module 2 uses structured light 3D scanning technology to perform 3D modeling of the workpiece 14, including: a high-definition camera 21, an LED flicker-free light 22, and a projector 23; the high-definition camera 21, the LED flicker-free light 22, and the projector 23 are evenly and symmetrically distributed around the workpiece 14 to be inspected as the center point, on the side wall, the roof, and the ground in the middle of the inspection lead room 1, forming a multi-dimensional central matrix module.

[0038] The LED flicker-free light 22 illuminates the workpiece surface evenly with grid-like light through the projector 23, and the high-definition camera 21 captures photos of the workpiece from various angles and transmits the captured data to the AI ​​control center 13 for 3D modeling.

[0039] The through-beam grating ruler 10 uses a standard high-precision measuring grating ruler to scan and measure the actual height of the workpiece 14, and transmits the measurement data to the AI ​​control center 13 to further correct the dimensions of the generated three-dimensional model, thus obtaining the final model digital data that is 1:1 with the actual workpiece.

[0040] The conveyor line 5 adopts a standard flexible belt conveyor line, using servo motor control for precise positioning. The middle support plate and frame of the conveyor line 5 have a hollow structure to allow the matrix camera module 2 below to perform lower contour scanning and modeling of the workpiece 14. The conveyor belt 51 of the conveyor line 5 is made of transparent PVC material, allowing the matrix camera module 2 to scan and model the lower contour of the workpiece 14 through the conveyor belt 51.

[0041] The AI ​​control center 13 is the core brain of this detection device, including: industrial control computer center, automatic control module, modeling and calculation module, intelligent program calculation module, X-ray imaging processing module, and detection image analysis module; all modules coordinate and work together to complete the entire process of intelligent X-ray detection of the workpiece.

[0042] The control method of AI Control Center 13 is as follows:

[0043] As the core control center, the industrial control computer center coordinates the various modules to work together in an orderly manner, communicates with the testing personnel through the human-machine interface, and summarizes and stores various data during the testing process.

[0044] The automatic control module is the drive control center of this device. It receives overall coordinated control from the industrial control computer center and is responsible for the transmission control of all operating actions, including: the drive transmission control of the production line, the drive control of the horizontal and vertical adjustment of the multi-axis robot 4 carried by the robot moving mechanism 3, the drive control of the rotation and bending of each joint of the multi-axis robot 4, and the drive control of the adjustment, conversion and workpiece gripping of the front-end pneumatic gripper.

[0045] The modeling and calculation module receives overall collaborative control from the industrial control computer center. It performs structured light 3D scanning of the workpiece 14 from various angles through the matrix camera module 2, performs centralized modeling and calculation on multiple sets of scan data images, and synthesizes a 3D model module of the workpiece 14. Then, it scans and measures the actual height data of the workpiece 14 through the through-beam grating ruler 10, performs correction, and obtains the final 1:1 3D model digital data of the actual workpiece.

[0046] The intelligent program calculation module receives overall collaborative control from the industrial control computer center. It intelligently analyzes the 3D modeling digital data generated in the modeling calculation module. By analyzing the external structure, dimensions, and specific outline of workpiece 14, and combining the optimal detection imaging image size, radiation intensity, transmission thickness, and image transmission angle and position information provided by the X-ray imaging processing module, it intelligently calculates and analyzes the optimal detection scheme. The detection scheme includes: selection of gripping method: three-jaw clamp 42 for round workpieces, two-jaw clamp 41 for square workpieces, and irregular workpiece clamp 43 for slender and flat workpieces; selection of detection position: based on the workpiece shape, size data, and X-ray penetration... The selection of the optimal imaging angle and movement sequence is determined based on the thickness and imaging area of ​​the workpiece 14. The selection of X-ray intensity parameters involves choosing suitable X-ray tube current and voltage parameters according to the actual thickness and position information of the workpiece 14, and determining the X-ray intensity. The selection of movement steps is based on the previous gripping position and the imaging detection area. Specifically, it involves gripping a rectangular workpiece and then moving it parallel to sequentially detect all positions of the entire workpiece; or gripping a cylindrical workpiece and then rotating it sequentially to complete the detection of all positions of the entire workpiece; or gripping an irregularly shaped workpiece and then flipping it sequentially to complete the detection of all positions of the entire workpiece. Finally, the optimal detection scheme is intelligently calculated and the results are sent to the industrial control computer center.

[0047] The industrial control computer center coordinates with other modules to execute the optimal testing plan, driving the multi-axis robotic arm 4 to pick up the workpiece 14 and move it to the testing position, performing rotational and parallel movements. Simultaneously, the X-ray imaging processing module is activated, and the X-ray machine 8 and imager 6 are turned on to perform automatic X-ray inspection. After the inspection is completed, the X-ray machine is turned off and the workpiece 14 is placed on the conveyor line 5 and transported out of the lead-lined inspection room 1.

[0048] The X-ray imaging processing module receives overall coordinated control from the industrial control computer center. It transmits the X-ray intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the X-ray machine to the intelligent program calculation module. After calculating the optimal workpiece inspection plan, it starts the X-ray machine, adjusts the input tube current and tube voltage of the X-ray machine 8, outputs the X-ray intensity of the execution plan, and simultaneously turns on the imager 6 to receive X-rays passing through the workpiece for imaging inspection. It then transmits the inspection image information to the inspection image analysis module. After the inspection is completed, it turns off the X-ray machine imager according to the instructions.

[0049] The detection image analysis module receives overall collaborative control from the industrial control computer center. After receiving the detection image information, it processes the image using software. Based on the requirements for contrast, sensitivity, and clarity of the detection image, it judges whether the workpiece meets the X-ray detection qualification standard. If it meets the standard, it is marked, and the detection data is archived and saved.

[0050] The robotic arm moving mechanism 3 uses a linear guide rail slider for guidance, and a servo motor drives a gear rack to move, driving the multi-axis robotic arm 4 on the upper part of the lead inspection room 1 in both the horizontal and vertical directions for movement and positioning.

[0051] The multi-axis robotic arm 4 adopts standard robotic arm technology, which can flex and retract its mechanical gripper to grasp workpieces and move and rotate them for scanning and inspection. It includes: a two-jaw gripper 41, a three-jaw gripper 42, an irregularly shaped workpiece gripper 43, a robotic handpiece holder 44, a robotic arm rear arm 45, a robotic arm intermediate arm 46, a robotic arm rear arm 47, and a robotic arm pneumatic gripper conversion seat 48.

[0052] A robotic arm base 44 is installed below the robotic arm moving mechanism 3. The robotic arm base 44 contains a rotary bearing and a drive motor, which can rotate. A robotic arm rear arm 45 is connected to the robotic arm base 44 via a hinge and can rotate and bend via a motor. A robotic arm intermediate arm 46 is connected to the robotic arm rear arm 45 via a hinge and can rotate and bend via a motor. A robotic arm rear arm 47 is connected to the robotic arm intermediate arm 46 via a hinge and can rotate and bend via a motor. A robotic arm gripper conversion seat 48 is connected to the lower end of the robotic arm rear arm 47. The robotic arm rear arm 47 contains a rotary bearing and a drive motor, which can drive the robotic arm gripper conversion seat 48 to rotate. The front end of the robotic arm gripper conversion seat 48 is a convertible spherical adjustment mechanism. A two-jaw gripper 41, a three-jaw gripper 42, and an irregular workpiece gripper 43 are connected to the top. One set of grippers is at the bottom, and the other two sets of grippers are evenly distributed at a certain angle on both sides. They can be automatically rotated and switched as needed.

[0053] The multi-axis robot arm 4 features an automatically convertible and adjustable gripper at its front end, including a two-jaw gripper 41, a three-jaw gripper 42, and an irregularly shaped workpiece gripper 43. The appropriate gripper is matched to the shape of the workpiece being inspected: long and square workpieces are matched with the two-jaw gripper 41, cylindrical and polygonal workpieces with the three-jaw gripper 42, and slender and flat workpieces with the irregularly shaped workpiece gripper 43. The spherical rotating structure of the gripper at the front end of the multi-axis robot arm 4 rotates the corresponding gripper to the lowest working position according to the workpiece shape. If the shape of the workpiece to be inspected does not match the gripper, the robot arm gripper conversion seat 48 is automatically rotated and adjusted to the corresponding gripper.

[0054] One type of detection method using an AI-powered intelligent X-ray inspection device for small workpieces of various sizes:

[0055] Step 1: The workpiece 14 to be inspected is conveyed to the conveyor line 5 and then sequentially passed through the protective lead curtain 12 and the outer protective lead cover 11 to be positioned in the middle of the lead inspection room 1.

[0056] Step 2: The AI ​​control center 13 starts working. The modeling and calculation module receives overall collaborative control from the industrial control computer center. The matrix camera module 2 performs structured light 3D scanning of the workpiece 14 from multiple angles, including the side, top, and bottom. The LED flicker-free light 22 transmits grid-like light evenly onto the workpiece surface through the projector 23. The high-definition camera 21 captures photos of the workpiece from various angles. Multiple sets of scanned images are centrally modeled and calculated to synthesize a 3D model module of the workpiece 14. Then, the through-beam grating ruler 10 scans and measures the actual height data of the workpiece 14, performs correction, and obtains the final 1:1 3D model digital data that is identical to the actual workpiece.

[0057] Step 3: The intelligent program calculation module receives overall collaborative control from the industrial control computer center, and performs intelligent analysis on the three-dimensional modeling digital data generated in the modeling calculation module. It analyzes the external structure, external dimensions, and specific external contour of workpiece 14, and performs comprehensive analysis by combining the radiation intensity information, corresponding penetration thickness information, and detection sensitivity information provided by the radiation imaging processing module. It intelligently calculates and analyzes the optimal detection scheme, selects the gripping method, selects the detection position, selects the radiation intensity parameters, selects the motion steps, and sends the calculation results to the industrial control computer center.

[0058] Step 4: The industrial control computer center coordinates with the X-ray imaging processing module to turn on the X-ray machine 8 according to the execution plan, adjusts the input tube current and tube voltage of the X-ray machine 8, outputs the X-ray intensity of the execution plan, and simultaneously turns on the imager 6 to receive X-rays passing through the workpiece for imaging detection.

[0059] Step 5: The industrial control computer center coordinates with the automatic control module to drive the robotic arm moving mechanism 3 to move according to the optimal scheme calculated by intelligent calculation. The multi-axis robotic arm 4 is carried to the position directly above the workpiece 14. The multi-axis robotic arm 4 is driven to automatically rotate and adjust the robotic arm gripper conversion seat 48 to the corresponding matching fixture. The front end gripper is extended to grab the workpiece 14. After the X-ray is turned on synchronously, the workpiece is driven to complete the translation, rotation or flipping movement according to the scheme. After the inspection is completed, the workpiece is returned to the conveyor line 5, the X-ray is turned off, and the conveyor line 5 is driven to send the workpiece 14 out of the inspection lead room 1.

[0060] Although this patent has been described with reference to preferred embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of this patent. In particular, the technical features mentioned in the various embodiments can be combined in any manner, provided there is no structural conflict. This patent is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

[0061] In the description of this patent, terms such as "upper," "lower," "left," "right," "horizontal," "inner," and "outer," which indicate direction or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. These are used solely for descriptive purposes and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this patent. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0062] Furthermore, it should be noted that, in the description of this patent, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this patent according to the specific circumstances.

[0063] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An AI intelligent multi-specification small workpiece X-ray detection device, characterized in that: include: The system includes a lead testing room, a matrix camera module, a robotic arm movement mechanism, a multi-axis robotic arm, a conveyor line, an imager, an imager support and adjustment mechanism, an X-ray machine, an X-ray machine support and adjustment mechanism, a through-beam grating ruler, an outer protective lead cover, a protective lead curtain, and an AI control center. The robotic arm movement mechanism is installed on the top frame of the lead testing room, and a multi-axis robotic arm is installed below it. An imager support and adjustment mechanism is installed on the front side wall of the lead testing room, with the imager mounted at its front end. An X-ray machine support and adjustment mechanism is installed on the rear side wall of the lead testing room, with the X-ray machine mounted at its front end. The X-ray receiving area of ​​the imager corresponds to the X-ray generating window of the X-ray machine on the same axis. A conveyor line is installed in the middle of the lead testing room, with both ends extending beyond the testing area of ​​the lead testing room. The inspection room has external protective lead covers installed at both ends of the inspection window and above the conveyor line. Protective lead curtains are installed at the ends of the protective lead covers. The inspection room, protective lead covers, and protective lead curtains form a closed space. Multiple sets of matrix camera modules are evenly distributed in the middle of the inner side wall of the inspection room, pointing towards the workpiece at the center of the conveyor line from the side and diagonally, and scanning and modeling the workpiece. Multiple sets of matrix camera modules are evenly distributed at the top and bottom of the inspection room, pointing towards the workpiece at the center of the conveyor line from the top and bottom, respectively, and scanning and modeling the workpiece. Symmetrical through-beam grating rulers are installed on the diagonal side wall of the inspection room, with the center of the conveyor line as the center point, to measure and correct the actual size of the workpiece. An AI control center is installed outside the inspection room. The lead testing room uses a steel frame as its skeleton, and protective lead plates are installed on the outside of the skeleton for radiation protection. The lead plates are fixed to the skeleton by welding thin steel plates on both sides with lead plates sandwiched in the middle. The matrix camera module uses structured light 3D scanning technology to create a 3D model of the workpiece. It includes a high-definition camera, a flicker-free LED light, and a projector. The high-definition camera, flicker-free LED light, and projector are evenly and symmetrically distributed around the workpiece to be inspected, on the side walls, the roof, and the ground in the middle of the inspection room, forming a multi-dimensional central matrix module. The conveyor system adopts a standard flexible belt conveyor system, which uses servo motors to control the transmission and precisely control the position of the conveyor. The AI ​​control center is the core brain of this inspection device, including: industrial control computer center, automatic control module, modeling and calculation module, intelligent program calculation module, X-ray imaging processing module, and inspection image analysis module; all modules coordinate and work together to complete the entire process of intelligent X-ray inspection of the workpiece. The robotic arm moving mechanism uses linear guide rails and sliders for guidance, and servo motors drive gears and racks for movement. It drives the multi-axis robotic arm on the upper part of the lead room in both horizontal and vertical directions to move and position itself in the upper space of the lead room. The multi-axis robotic arm employs standard robotic arm technology, capable of retracting and flexing its gripper to grasp workpieces and moving and rotating them for scanning and inspection. It includes: a two-jaw gripper, a three-jaw gripper, a shaped workpiece gripper, a robotic arm holder, a robotic arm rear arm, a robotic arm intermediate arm, and a robotic arm pneumatic gripper conversion base. The robotic arm holder is mounted below the robotic arm's moving mechanism, containing a rotary bearing and drive motor for rotational movement. The robotic arm rear arm is connected to the robotic arm holder via a hinge and is driven by a motor for rotational bending. The robotic arm intermediate arm is connected to the robotic arm rear arm via a hinge. The robot arm is connected to the rear arm via a hinge and can rotate and bend as driven by a motor. The lower end of the rear arm is connected to a gripper conversion seat. The rear arm contains a rotary bearing and a drive motor, which drives the gripper conversion seat to rotate. The front end of the gripper conversion seat has a convertible spherical adjustment mechanism, and it is equipped with a two-jaw gripper, a three-jaw gripper, and a gripper for irregularly shaped workpieces. One set of grippers is located at the bottom, and the other two sets of grippers are evenly distributed at a certain angle on both sides, automatically rotating and switching as needed.

2. The AI intelligent multi-specification small workpiece X-ray detection device according to claim 1, characterized in that: The LED flicker-free light projector evenly illuminates the workpiece surface with grid-like light. A high-definition camera captures images of the workpiece from various angles and transmits the captured data to the AI ​​control center for 3D modeling. A through-beam grating ruler scans the workpiece to measure its actual height and transmits the measurement data to the AI ​​control center for further dimensional correction of the generated 3D model, resulting in a final 1:1 model digital data that matches the actual workpiece.

3. The AI intelligent multi-specification small workpiece X-ray detection device according to claim 1, characterized in that: The middle tray and frame of the conveyor line have a hollow structure, and the conveyor belt of the conveyor line is made of transparent PVC material. The matrix camera module can scan and model the lower contour of the workpiece through the conveyor belt.

4. The AI intelligent multi-specification small workpiece X-ray detection device according to claim 1, characterized in that: The multi-axis robot's front-end mechanical gripper is an automatically convertible and adjustable fixture, including: a two-jaw gripper, a three-jaw gripper, and an irregularly shaped workpiece gripper. The appropriate gripper is matched according to the shape of the workpiece being inspected: long and square workpieces are matched with two-jaw grippers, cylindrical and polygonal workpieces with three-jaw grippers, and slender and flat workpieces with irregularly shaped workpiece grippers. The spherical rotating structure of the multi-axis robot's front-end mechanical gripper rotates the corresponding gripper to the lowest working position according to the workpiece shape. If the shape of the workpiece to be inspected does not match the gripper, the robot's gripper conversion seat is automatically rotated and adjusted to the corresponding gripper.

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