Electrode cap testing equipment

Abstract

This application provides an electrode cap testing device. The device includes a frame and a testing assembly. The testing assembly is mounted on the frame and includes a first testing head and an optical fiber sensor connected to the first testing head. The first testing head has a first channel. The optical fiber sensor includes a first surface and a first transmitting port and a first receiving port disposed on the first surface. Both the first transmitting port and the first receiving port are aligned with the first electrode cap through the first channel, wherein the light rays passing through the first transmitting port and the light rays passing through the first receiving port are parallel. Thus, with both the first transmitting port and the first receiving port disposed on the first surface, and the emitted and received light rays optically parallel, the testing is more accurate, and the positioning precision requirement is lower.

Description

Technical Field

[0001] This application relates to the field of automobile manufacturing, specifically to an electrode cap testing device. Background Technology

[0002] Currently, the shape of the electrode tip is one of the key factors affecting welding quality, and its geometry is directly related to the current density distribution. As the diameter of the electrode tip increases, the current density decreases; conversely, as the diameter decreases, the current density increases accordingly. Therefore, in actual production, electrodes undergo progressive wear during continuous welding operations. This necessitates an electrode trimming process to rework the worn electrode tip to a standard shape. However, in existing technologies, operators must interrupt the production line to access the workstation for manual inspection. This process not only significantly reduces production efficiency but also incurs considerable human resource costs. Utility Model Content

[0003] This application provides an electrode cap detection device through multiple embodiments, aiming to solve the problem of high maintenance costs after electrode wear.

[0004] In a first aspect, this application provides an electrode cap testing device. The electrode cap testing device includes a frame and a testing assembly. The testing assembly is mounted on the frame and includes a first testing head and an optical fiber sensor connected to the first testing head. The first testing head has a first channel. The optical fiber sensor includes a first surface and a first transmitting port and a first receiving port disposed on the first surface. The first transmitting port and the first receiving port are both aligned with the first electrode cap through the first channel, wherein the light passing through the first transmitting port and the light passing through the first receiving port are parallel.

[0005] Thus, both the first transmitting port and the first receiving port are located on the first surface, and the emitted light and the receiving optics are arranged in parallel, making the detection more accurate and the positioning accuracy requirement lower.

[0006] Optionally, the detection assembly further includes a second detection head, which has a second channel. The first detection head and the second detection head are arranged opposite to each other for docking with the first electrode cap and the second electrode cap, respectively. The fiber optic sensor is disposed between the first detection head and the second detection head. The fiber optic sensor further includes a second surface and a second transmitting port and a second receiving port disposed on the second surface. The second transmitting port and the second receiving port are both aligned with the second electrode cap through the second channel, wherein the light passing through the second transmitting port and the light passing through the second receiving port are parallel.

[0007] In this way, the dual detection heads can simultaneously and efficiently detect both the first and second electrode caps, improving detection efficiency. Furthermore, both the second transmitting port and the second receiving port are located on the second surface, and the emitted light and the receiving optical path are parallel, resulting in more accurate detection and lower positioning precision requirements.

[0008] Optionally, both the first detection head and the second detection head are formed with receiving grooves. The first channel passes through the receiving groove of the first detection head and connects to the first electrode cap. The second channel passes through the second detection head and connects to the second electrode cap. The receiving groove is used to position the first electrode cap and the second electrode cap.

[0009] In this way, the receiving groove provides a clear installation reference for the electrode cap through physical constraints, avoiding optical path alignment errors. At the same time, the first and second channels penetrate the receiving groove, which can strictly limit the light within the preset path and avoid obstructing the light path.

[0010] Optionally, a waterproof column is formed on the side of the second detection head near the fiber optic sensor. The detection assembly also includes a sealing gasket, which is disposed between the first detection head and the fiber optic sensor. Both the waterproof column and the sealing gasket are used to prevent external water from entering between the first detection head and the second detection head.

[0011] In this way, the installation of sealing gaskets and waterproof columns can prevent optical path contamination, electrical short circuits, or sensor failure caused by liquid intrusion, thus ensuring the long-term stability of the electrode cap detection signal and the service life of the equipment.

[0012] Optionally, the first detection head includes a first mounting hole, and the second detection head includes a second mounting hole. The first mounting hole is used to cooperate with the second mounting hole to achieve the positioning and installation of the first detection head and the second detection head.

[0013] This ensures the accurate relative positions of the first and second detection heads after installation, effectively avoiding signal measurement errors caused by misalignment or offset, and guaranteeing the reliability and long-term stability of the detection components.

[0014] Optionally, the electrode cap detection device further includes an optical fiber amplifier, which is used to amplify the optical signal received by the receiving port and compare the amount of reflection with a set value.

[0015] This enhances the response capability of the detection component 20 to weak signals, and by quantifying the intensity of reflection, it significantly improves the accuracy and reliability of the detection.

[0016] Optionally, the electrode cap testing device further includes a fixing base, which includes a first accommodating cavity and a second accommodating cavity that communicate with each other. The first accommodating cavity is used to house the fiber optic amplifier, and the second accommodating cavity is used to house the testing component.

[0017] This optimizes the internal structure of the electrode cap testing equipment, saves installation space, and ensures that the core optical path between the fiber amplifier and the testing components is in a stable, accurate, and protected relative position.

[0018] Optionally, the electrode cap testing device further includes a dust cover, which is slidably fitted onto the fixed base and can slide along the length of the fixed base to cover or expose the testing component.

[0019] In this way, the detection components can be flexibly covered or exposed to cope with non-detection and detection states, preventing the detection components from being exposed and contaminated in the non-detection state.

[0020] Optionally, the electrode cap testing device further includes a guide block and an elastic element disposed on the guide block, the guide block being disposed on the fixed base and connected to the dust cover through the elastic element.

[0021] In this way, the guide block ensures that the dust cover slides smoothly along the predetermined trajectory, preventing it from sliding off-center or getting stuck. At the same time, the elastic connection between the guide block and the dust cover provides a certain degree of elastic compensation, further enhancing the sealing and stability of the dust cover.

[0022] Optionally, the electrode cap testing device further includes a floating unit, which is disposed on the frame and can move vertically relative to the frame. The fixed base is disposed on the floating unit, and the floating unit enables the fixed base to drive the testing component to have elastic margin in at least two vertical directions relative to the frame.

[0023] In this way, the floating unit allows the electrode cap testing equipment to perform testing work more flexibly, avoiding damage to the testing components or electrode cap caused by rigid collisions.

[0024] This application provides an electrode cap testing device. The device includes a frame and a testing assembly. The testing assembly, mounted on the frame, includes a first testing head and an optical fiber sensor connected to the first testing head. The first testing head has a first channel. The optical fiber sensor includes a first surface and a first transmitting port and a first receiving port disposed on the first surface. Both the first transmitting port and the first receiving port are aligned with the first electrode cap through the first channel, wherein the light rays passing through the first transmitting port and the light rays passing through the first receiving port are parallel. Thus, with both the first transmitting port and the first receiving port disposed on the first surface, and the emitted and received light rays optically parallel, the testing is more accurate, and the positioning precision requirement is lower. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of an electrode cap testing device provided in one embodiment of this specification.

[0026] Figure 2 Another structural schematic diagram of the electrode cap testing device provided for one embodiment of this specification.

[0027] Figure 3 This is another structural schematic diagram of an electrode cap testing device provided as an embodiment of this specification.

[0028] Figure 4 This is another structural schematic diagram of the electrode cap testing device provided in one embodiment of this specification.

[0029] Figure 5 This is another structural schematic diagram of the electrode cap testing device provided in one embodiment of this specification.

[0030] Figure 6 This is another structural schematic diagram of the electrode cap testing device provided in one embodiment of this specification.

[0031] Figure 7 This is another structural schematic diagram of the electrode cap testing device provided in one embodiment of this specification.

[0032] Figure 8 This is another structural schematic diagram of the electrode cap testing device provided in one embodiment of this specification.

[0033] Figure 9 This is another structural schematic diagram of the electrode cap testing device provided in one embodiment of this specification.

[0034] Explanation of reference numerals in the attached figures 100. Electrode cap testing equipment; 10. Frame; 20. Testing component; 21. First testing head; 211. First channel; 212. First mounting hole; 213. First positioning pin hole; 22. Second testing head; 221. Second channel; 222. Second mounting hole; 223. Second positioning pin hole; 23. Fiber optic sensor; 231. First surface; 232. Second surface; 233. First transmitting port; 234. Second transmitting port; 235. First receiving port; 236. Second receiving port; 24. Waterproof column; 25. Sealing gasket; 26. Receiving groove; 31. First electrode cap; 32. Second electrode cap; 40. Fiber optic amplifier; 50. Fixing base; 51. First receiving cavity; 52. Second receiving cavity; 60. Dust cover; 70. Guide block; 71. Elastic element; 80. Floating unit. Detailed Implementation

[0035] The technical solutions in the embodiments of this specification will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0036] In this specification, the accompanying drawings are not necessarily drawn to scale, and local features may be enlarged or reduced to show the details of the local features more clearly.

[0037] Unless otherwise stated, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of this specification. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items. The singular forms "a," "the," and "the" as used in this specification and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise.

[0038] In the description of this specification, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this specification, "a plurality of" means two or more, unless otherwise explicitly specified.

[0039] In the description of this specification, the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "height," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the purpose of simplifying the description in this specification and do not indicate that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. In other words, they should not be construed as limitations on this application.

[0040] In the description of this specification, unless otherwise expressly defined, the terms "installation," "connection," "joining," "fixing," "setting," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can also refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this specification according to the specific circumstances.

[0041] Currently, with the rapid automation of manufacturing sectors such as automobiles, the requirements for the automation rate of production lines are constantly increasing. In actual continuous production, electrodes experience progressive wear due to high temperature and pressure. To maintain process stability, it is necessary to periodically restore the standard geometry of the electrodes through a trimming process. However, the shape of the electrode tip is one of the key factors affecting welding quality, and its geometric dimensions are directly physically related to the current density distribution. As the diameter of the electrode tip increases, the current density decreases; conversely, as the diameter decreases, the current density increases accordingly. Current inspection methods have significant bottlenecks: maintenance personnel need to stop the production line and enter the welding station for manual inspection. In existing inspection methods, when using optical inspection, the emission and return holes of the light source often need to be set at different angles, and the electrode cap needs to be accurately placed in the corresponding position. This requires high positioning accuracy, is difficult for operators, and results in low inspection accuracy.

[0042] For example, as automakers increasingly demand higher production cycle times, the electrode caps on welding torches in automotive welding lines require re-grinding after a certain number of welding passes. The quality of the re-grinded electrode caps typically requires manual inspection at the production station, stopping the line operation before restarting. This traditional method not only results in lost production capacity but also heavily relies on the experience of the personnel. Subjective visual assessment struggles to quantify key parameters such as end-face diameter and concentricity, and is ineffective in identifying defects like microscopic cracks. Especially in automotive manufacturing, the widespread use of high-strength steel and galvanized steel has significantly increased sensitivity to electrode condition. Existing inspection methods are no longer sufficient to meet the requirements of zero-defect manufacturing.

[0043] Please see Figures 1 to 4 This application provides an electrode cap testing device 100. The electrode cap testing device 100 includes a frame 10 and a testing component 20. The testing component 20 is disposed on the frame 10 and includes a first testing head 21 and an optical fiber sensor 23 connected to the first testing head 21. The first testing head 21 forms a first channel 211. The optical fiber sensor 23 includes a first surface 231 and a first transmitting port 233 and a first receiving port 235 disposed on the first surface 231. The first transmitting port 233 and the first receiving port 235 are both aligned with the first electrode cap 31 through the first channel 211, wherein the light passing through the first transmitting port 233 and the light passing through the first receiving port 235 are parallel.

[0044] Thus, both the first transmitting port 233 and the first receiving port 235 are located on the first surface 231, and the emitted light and the received light are arranged in parallel, making the detection more accurate and the positioning accuracy requirement lower.

[0045] In this embodiment, the frame 10 of the electrode cap testing device 100 is fixedly mounted on a platform such as the ground, and the testing component 20 is located at the end of the frame 10 away from the platform, facilitating rapid testing of the electrode caps. The testing component 20 includes a first testing head 21 and an optical fiber sensor 23, wherein the optical fiber sensor 23 is connected to the first testing head 21, so that the detected state information of the electrode cap surface can be collected and processed by the optical fiber sensor 23 in the first instance, and the electrode cap needs maintenance based on the state information of the electrode cap surface. Specifically, the first testing head 21 forms a first channel 211, and the first surface 231 of the optical fiber sensor 23 is provided with a first transmitting port 233 and a first receiving port 235. In this way, both the first transmitting port 233 and the first receiving port 235 can be aligned with the first electrode cap 31 through the first channel 211, facilitating the fiber optic sensor 23 to emit light from the first transmitting port 233. The emitted light then passes through the first channel 211 formed by the first detection head 21 and illuminates the electrode cap. The light can be reflected on the electrode cap, and a portion of the reflected light can be reflected back to the first receiving port 235 through the first channel 211, thus completing the acquisition of light. This means that the surface condition information of the electrode cap is acquired, allowing for the determination of whether the electrode cap requires maintenance. Thus, by analyzing changes in the optical signal, the surface condition of the electrode cap can be assessed. For example, the brightness, integrity, and size of the reflected light spot can be used to make corresponding judgments. In this embodiment, the light spot can be compared with a set value using a photosensitive instrument to avoid human evaluation and ensure the accuracy of the detection.

[0046] Furthermore, both the first transmitting port 233 and the first receiving port 235 are aligned with the first electrode cap 31 through the first channel 211, wherein the light rays passing through the first transmitting port 233 and the light rays passing through the first receiving port 235 are parallel. This optical path design, which aligns the first transmitting port 233 and the first receiving port 235 parallel to the electrode cap through the same channel, forms a parallel optical path for light emission and reflection, resulting in more accurate detection and lower positioning precision requirements. Simultaneously, the dual optical paths sharing the same physical channel saves internal space in the first detection head 21, reduces structural complexity, and makes it easier to install and deploy in the limited space at the end of the rack 10. Furthermore, the first transmitting port 233 and the first receiving port 235 are positioned on the same plane, allowing for high-precision relative position detection of the electrode cap during assembly simply by accurately positioning it against this plane. This avoids optical detection problems caused by operators repeatedly adjusting the transmitting and receiving ports in different positions.

[0047] In this embodiment, the specific installation position of the detection component 20 at one end of the frame 10 is not limited to meet various requirements. For example, the detection component 20 can be installed on the side of one end of the frame 10 (such as the left or right side, front or rear side); or, the detection component 20 can also be installed directly above one end of the frame 10, that is, the detection component 20 can be installed at the top of the frame 10. In this way, the first detection head 21 can face in any direction.

[0048] Please see Figure 3 and Figure 4 In some embodiments, the detection assembly 20 further includes a second detection head 22, which has a second channel 221. The first detection head 21 and the second detection head 22 are disposed opposite to each other for docking with the first electrode cap 31 and the second electrode cap 32, respectively. The fiber optic sensor 23 is disposed between the first detection head 21 and the second detection head 22. The fiber optic sensor 23 also includes a second surface 232 and a second emission port 234 and a second reception port 236 disposed on the second surface 232. The second emission port 234 and the second reception port 236 are both aligned with the second electrode cap 32 through the second channel 221, wherein the light passing through the second emission port 234 and the light passing through the second reception port 236 are parallel.

[0049] In this way, the dual detection heads can simultaneously and efficiently detect the first electrode cap 31 and the second electrode cap 32, improving detection efficiency. Meanwhile, both the second transmitting port 234 and the second receiving port 236 are located on the second surface 232, and the emitted light and the receiving optical are parallel, making the detection more accurate and requiring lower positioning precision.

[0050] In this embodiment, the detection component 20 further includes a second detection head 22. The first detection head 21 and the second detection head 22, which are arranged opposite to each other, can be used to dock with the first electrode cap 31 and the second electrode cap 32 in different directions, respectively. In this way, the two detection heads can simultaneously detect the first electrode cap 31 and the second electrode cap 32, which can significantly improve the working efficiency of the electrode cap detection device 100.

[0051] Furthermore, the fiber optic sensor 23 is positioned between the first detection head 21 and the second detection head 22. In this way, one fiber optic sensor 23 can simultaneously serve the operation of both detection heads, making the structure of the detection assembly 20 more compact, optimizing spatial layout and resource integration, and avoiding the space waste and cost increases caused by independently configuring fiber optic sensors 23 for each workstation. Simultaneously, since the first detection head 21 and the second detection head 22 share the same light source and processing unit, the optical signal characteristics and judgment criteria of the two detection workstations remain highly consistent, eliminating the risk of quality misjudgment due to differences in the fiber optic sensor 23 and ensuring detection consistency. In addition, welding guns are often clamp-type devices with two detection heads, allowing them to be approached from both ends of the first detection head 21 and the second detection head 22 simultaneously for synchronous detection.

[0052] Specifically, the second detection head 22 has a second channel 221, and the second surface 232 of the fiber optic sensor 23 has a second transmitting port 234 and a second receiving port 236. Thus, the second transmitting port 234 and the second receiving port 236 can both be aligned with the second electrode cap 32 through the second channel 221, facilitating the fiber optic sensor 23 to emit light from the second transmitting port 234. The emitted light then passes through the second channel 221 formed by the second detection head 22 and illuminates the electrode cap. The light can be reflected on the electrode cap, and a portion of the reflected light can be reflected back to the second receiving port 236 through the second channel 221, thereby completing the light acquisition. In other words, it completes the acquisition of surface condition information of the electrode cap, thereby determining whether the electrode cap needs maintenance. In this way, by analyzing changes in the optical signal, the surface condition of the electrode cap can be assessed.

[0053] Furthermore, the fiber optic sensor 23 employs reflective detection, with the emission and reception angles of the light source perpendicular to the detection surface, resulting in better detection accuracy, high repeatability, and simpler installation. Both the second emission port 234 and the second reception port 236 are aligned with the second electrode cap 32 via the second channel 221, where the light rays passing through the second emission port 234 and the second reception port 236 are parallel. This optical path design, aligning the second emission port 234 and the second reception port 236 parallel to the electrode cap via the same channel, creates parallel optical paths for light emission and reflection, leading to more accurate detection and lower positioning accuracy requirements. Simultaneously, the dual optical paths sharing the same physical channel saves internal space in the second detection head 22, reduces structural complexity, and makes it easier to install and deploy in the limited space at the end of the rack 10.

[0054] Please see Figure 3 and Figure 4In some embodiments, both the first detection head 21 and the second detection head 22 are formed with receiving grooves 26. A first channel 211 passes through the receiving groove 26 of the first detection head 21 and connects to the first electrode cap 31. A second channel 221 passes through the second detection head 22 and connects to the second electrode cap 32. The receiving groove 26 is used to position the first electrode cap 31 and the second electrode cap 32.

[0055] Thus, the receiving groove 26 provides a clear installation reference for the electrode cap through physical constraints, avoiding optical path alignment errors. At the same time, the first channel 211 and the second channel 221 penetrate the receiving groove 26, which can strictly limit the light within the preset path and avoid obstructing the light path.

[0056] In this embodiment, when it is necessary to detect the first electrode cap 31 and the second electrode cap 32, the first electrode cap 31 can be received and constrained into the receiving groove 26 of the first detection head 21, and the second electrode cap 32 can be received and constrained into the receiving groove 26 of the second detection head 22. In this way, the receiving groove 26 provides a clear installation reference for the electrode caps through physical constraint, reducing detection errors. Simultaneously, the receiving grooves 26 formed at the first detection head 21 and the second detection head 22 are respectively penetrated by the first channel 211 and the second channel 221, allowing the light emitted from the first emission port 233 and the second emission port 234 on the fiber optic sensor 23 to respectively illuminate the first electrode cap 31 and the second electrode cap 32, and the light is reflected and collected by the first receiving port 235 and the second receiving port 236. This strictly confines the light within a preset path, avoiding obstruction of the light path. The receiving groove 26 can limit the positioning of the first electrode cap 31 and the second electrode cap 32, ensuring that the first electrode cap 31 and the second electrode cap 32 are directly facing the first surface 231 and the second surface 232. It enables rapid and accurate positioning of the first electrode cap 31 and the second electrode cap 32. Combined with the through channel, the entire process can be completed smoothly, improving the efficiency and reliability of the detection.

[0057] Please see Figure 3 and Figure 4 In some embodiments, a waterproof column 24 is formed on the side of the second detection head 22 near the fiber optic sensor 23. The detection assembly 20 also includes a sealing gasket 25, which is disposed between the first detection head 21 and the fiber optic sensor 23. Both the waterproof column 24 and the sealing gasket 25 are used to prevent external water from entering between the first detection head 21 and the second detection head 22.

[0058] Thus, the sealing gasket 25 and waterproof column 24 can prevent optical path contamination, electrical short circuits or sensor failure caused by the intrusion of liquids or other dust impurities, ensuring the long-term stability of the electrode cap detection signal and the service life of the equipment.

[0059] In this embodiment, the first detection head 21 and the second detection head 22 are arranged opposite to each other, and the fiber optic sensor 23 is disposed between the first detection head 21 and the second detection head 22. Simultaneously, a sealing gasket 25 is disposed between the first detection head 21 and the fiber optic sensor 23, wherein the sealing gasket 25 can be made of a material with a certain degree of elasticity. After installation, the first detection head 21 and the fiber optic sensor 23 are tightly fitted to both sides of the sealing gasket 25. Thus, the sealing gasket 25 can further improve the sealing performance through elastic compensation, preventing external water from entering between the first detection head 21 and the fiber optic sensor 23.

[0060] A waterproof column 24 is formed on the side of the second detection head 22 near the fiber optic sensor 23. The waterproof column 24 can be made of an elastic material such as rubber. After installation, the second detection head 22 and the first detection head 21 can compress the waterproof column 24 to seal the gap on the side, thereby preventing external water from entering between the second detection head 22 and the fiber optic sensor 23. There can be two waterproof columns 24, each sealing a gap at a different location. In this way, the sealing gasket 25 and the waterproof column 24 can prevent optical path contamination, electrical short circuits, or sensor failure caused by liquid intrusion, ensuring the stability and service life of the electrode cap detection device 100.

[0061] Please see Figure 3 In some embodiments, the first detection head 21 includes a first mounting hole 212, and the second detection head 22 includes a second mounting hole 222. The first mounting hole 212 is used to cooperate with the second mounting hole 222 to achieve the positioning and installation of the first detection head 21 and the second detection head 22.

[0062] This ensures that the relative positions of the first detection head 21 and the second detection head 22 are accurate after installation, effectively avoiding signal measurement errors caused by misalignment or offset, and guaranteeing the reliability and long-term stability of the detection component 20.

[0063] In this embodiment, the first mounting hole 212 on the first detection head 21 and the second mounting hole 222 on the second detection head 22 can be aligned. Then, fasteners are passed through the aligned mounting holes and locked in place, thus firmly connecting the two and ensuring precise alignment. In this way, relying on the mounting hole mating, the first detection head 21 and the second detection head 22 can be quickly positioned and mechanically fixed. The structure is simple and reliable, easy to assemble and maintain, and ensures the accurate relative position of the first and second detection heads 22 after installation. This avoids signal measurement errors of the fiber optic sensor 23 caused by misalignment or offset, ensuring the reliability and long-term stability of the detection assembly 20.

[0064] In this embodiment, the specific number of the first mounting hole 212 and the second mounting hole 222 is not limited to meet various needs. For example, the number of the first mounting hole 212 and the second mounting hole 222 can both be 2 or 4. When the installation accuracy of the first detection head 21 and the second detection head 22 is required to be high, the number of the first mounting hole 212 and the second mounting hole 222 can both be set to 4; when the installation accuracy of the first detection head 21 and the second detection head 22 is required to be low, the number of the first mounting hole 212 and the second mounting hole 222 can both be set to 2.

[0065] In some embodiments, the first detection head 21 and the second detection head 22 further include a first positioning pin hole 213 and a second positioning pin hole 223, respectively. The first positioning pin hole 213 and the second positioning pin hole 223 are respectively provided and can be used to receive positioning pins to ensure that the first detection head 21 and the second detection head 22 are accurately positioned and installed.

[0066] Please see Figure 5 In some embodiments, the electrode cap detection device 100 further includes an optical fiber amplifier 40, which amplifies the optical signal received by the receiving port and compares the amount of reflection with a set value.

[0067] This enhances the response capability of the detection component 20 to weak signals, and by quantifying the intensity of reflection, it significantly improves the accuracy and reliability of the detection.

[0068] In this embodiment, the electrode cap detection device 100 also includes an optical fiber amplifier 40. The optical fiber amplifier 40 can amplify the optical information (or reflectance) on the surface of the electrode cap collected by the receiving port, improving the response capability of the detection component 20 to weak signals. Simultaneously, after detecting a certain electrode cap, the optical signal value (or reflectance) on the collected electrode cap can be compared with the preset optical signal value of the electrode cap detection device 100. If the collected optical signal value is greater than the preset optical signal value, it indicates that the electrode cap has passed the test and does not require maintenance; if the collected optical signal value is less than the preset optical signal value, it indicates that the electrode cap has failed the test and requires maintenance. Thus, by quantitatively judging the reflectance intensity, the accuracy and reliability of the detection can be significantly improved.

[0069] Please see Figure 1 , Figure 2 , Figure 5 and Figure 6 In some embodiments, the electrode cap detection device 100 further includes a mounting base 50, which includes a first accommodating cavity 51 and a second accommodating cavity 52 that are connected. The first accommodating cavity 51 is used to house the fiber optic amplifier 40, and the second accommodating cavity 52 is used to house the detection component 20.

[0070] In this way, the internal structure of the electrode cap testing device 100 is optimized, installation space is saved, and the core optical path between the fiber amplifier 40 and the testing component 20 is in a stable, accurate and protected relative position.

[0071] In this embodiment, the electrode cap testing device 100 further includes a mounting base 50 for centrally mounting the fiber optic amplifier 40 and the detection component 20. Specifically, the mounting base 50 has a first accommodating cavity 51 and a second accommodating cavity 52 that are interconnected. The first accommodating cavity 51 is used to house the fiber optic amplifier 40, and the second accommodating cavity 52 is used to house the detection component 20. This dual-cavity interconnected structure not only saves installation space and ensures that the core optical path between the fiber optic amplifier 40 and the detection component 20 is in a stable, precise, and protected relative position, but also ensures a stable relative position and smooth optical path transmission between the optical components. This helps reduce assembly errors, enhance overall rigidity, and improve signal consistency, ensuring the high precision and reliability of the electrode cap testing device 100.

[0072] Please see Figures 7 to 9 In some embodiments, the electrode cap detection device 100 further includes a dust cover 60, which is slidably fitted onto the mounting base 50 and can slide along the length of the mounting base 50 to cover or expose the detection component 20.

[0073] In this way, the detection component 20 can be flexibly covered or exposed to cope with non-detection and detection states, and to prevent the detection component 20 from being exposed and contaminated in the non-detection state.

[0074] In this embodiment, the electrode cap testing device 100 includes a slidable dust cover 60 to flexibly shield or expose the testing component 20. Specifically, the dust cover 60 is fitted outside the fixing base 50 and can slide freely along the length of the fixing base 50. When the electrode cap testing device 100 needs to test the electrode cap, the second electrode cap 32 at the lower end can reach a predetermined position and push open the dust cover 60, allowing the dust cover 60 to slide and expose the testing component 20, facilitating the testing component 20 to test the electrode cap. When the dust cover 60 is fully pushed open, the second electrode cap 32 faces the second testing head 22, while the first electrode cap 31 moves towards the first testing head 21 and clamps the testing component 20 with the second electrode cap 32, allowing the first electrode cap 31 and the second electrode cap 32 to enter the receiving groove 26 for testing. When the electrode cap testing device 100 completes the test and stops working, the first electrode cap 31 and the second electrode cap 32 leave the testing component 20, at which point the dust cover 60 can slide to shield and protect the testing component 20. In this way, the sliding opening mechanism facilitates quick execution of testing and maintenance operations, while the closed mechanism creates a continuous and stable sealed environment. This effectively prevents dust, moisture, oil, and other contaminants from corroding the detection component 20, avoiding optical path abnormalities, signal attenuation, or measurement distortion caused by contamination. This enhances the equipment's durability, ensures long-term stability of testing accuracy, and extends the service life of core components.

[0075] Please see Figures 6 to 9 In some embodiments, the electrode cap testing device 100 further includes a guide block 70 and an elastic element 71 disposed on the guide block 70. The guide block 70 is disposed on the fixed base 50 and connected to the dust cover 60 through the elastic element 71.

[0076] In this way, the guide block 70 can ensure that the dust cover 60 slides smoothly along the predetermined trajectory, preventing skewed sliding or jamming. At the same time, the elastic connection between the guide block 70 and the dust cover 60 can provide a certain degree of elastic compensation, further enhancing the sealing and stability of the dust cover 60.

[0077] In this embodiment, the guide block 70 is mounted on the fixed base 50 and connected to the dust cover 60, providing precise linear guidance for the sliding of the dust cover 60 and preventing deviation during sliding. Specifically, the guide block 70 is connected to the dust cover 60 via an elastic element 71 (such as a spring), providing power for the closing sliding of the dust cover 60, ensuring that the dust cover 60 can shield the detection component 20 when not in the detection state. Thus, one end of the elastic element 71 is connected to the guide block 70, and the other end is connected to the dust cover 60. When the dust cover 60 is closed, the guide block 70 can continuously apply controllable elastic power to the dust cover 60 through the elastic element 71. This allows the dust cover 60 to adaptively press and fit when closed, improving the sealing and dustproof effect, while also buffering impacts and reducing wear during frequent opening and closing, thus enhancing the mechanical reliability and service life of the equipment.

[0078] Please see Figure 1 and Figure 2 In some embodiments, the electrode cap detection device 100 further includes a floating unit 80, which is disposed on the frame 10 and is capable of moving vertically relative to the frame 10. A fixed seat 50 is disposed on the floating unit 80, and the floating unit 80 causes the fixed seat 50 to drive the detection component 20 to have elastic margin in at least two vertical directions relative to the frame 10.

[0079] Thus, the floating unit 80 allows the electrode cap testing device 100 to perform testing more flexibly, avoiding damage to the testing component 20 or the electrode cap caused by rigid collisions.

[0080] In this embodiment, the detection component 20 is positioned on the side of the frame 10 as an example. The electrode cap detection device 100 includes a floating unit 80, which is mounted on the frame 10 and can move vertically along the frame 10 (when the frame 10 is vertically fixed to a platform such as the ground). Simultaneously, the fixed base 50 is connected to the floating unit 80, meaning the entire detection component 20 can move vertically along with the floating unit 80, thus allowing for flexible detection of electrode caps at different heights. For example, when the electrode cap to be detected is at a lower position, the floating unit 80 can drive the fixed base 50 to move the detection component 20 downwards to a lower position; when the electrode cap to be detected is at a higher position, the floating unit 80 can drive the fixed base 50 to move the detection component 20 downwards to a higher position.

[0081] In some embodiments, the floating unit 80 enables the fixed base 50 to drive the detection component 20 to have elastic micro-motion in the XYZ directions relative to the frame 10. That is, the fixed base 50 has elastic margins in the up-down, left-right, and front-back positions, so that when the operator inserts the first electrode cap 31 and the second electrode cap 32 of the electric welding into the receiving groove 26 for detection, the fixed base 50 can absorb the operator's manual control error and improve the convenience of operation.

[0082] Furthermore, the floating unit 80 also possesses a certain degree of elasticity, allowing the fixed base 50 to drive the detection component 20 with a certain degree of elastic fine-tuning capability relative to the frame 10 in the XYZ spatial directions. This design of the floating unit 80 enables the electrode cap detection device 100 to perform detection work more flexibly, effectively absorbing mechanical assembly errors, workpiece positioning deviations, and impacts and vibrations generated during contact. This protects the electrode cap and detection component 20 from rigid collision damage and ensures a stable and precise alignment between the fiber optic sensor 23 and the electrode cap surface. This improves the reliability and service life of the electrode cap detection.

[0083] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0084] The functions and effects of this embodiment can be explained by referring to the foregoing implementation methods, and will not be repeated here.

[0085] It is understood that in the various embodiments of this specification, the sequence number of each process does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this specification.

[0086] It is understood that the various implementation methods described in this specification can be implemented individually or in combination, and the embodiments in this specification are not limited in this respect.

[0087] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the aforementioned method implementations, and will not be repeated here.

[0088] The above are merely specific embodiments of this specification, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this specification should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An electrode cap testing device, characterized in that, include: frame; The detection assembly mounted on the rack includes a first detection head and an optical fiber sensor connected to the first detection head. The first detection head has a first channel. The optical fiber sensor includes a first surface and a first transmitting port and a first receiving port disposed on the first surface. The first transmitting port and the first receiving port are both aligned with a first electrode cap through the first channel. The light rays passing through the first transmitting port and the light rays passing through the first receiving port are parallel.

2. The electrode cap testing device according to claim 1, characterized in that, The detection assembly further includes a second detection head, which forms a second channel. The first detection head and the second detection head are arranged opposite to each other for docking with the first electrode cap and the second electrode cap, respectively. The fiber optic sensor is disposed between the first detection head and the second detection head. The fiber optic sensor further includes a second surface and a second transmitting port and a second receiving port disposed on the second surface. The second transmitting port and the second receiving port are both aligned with the second electrode cap through the second channel, wherein the light passing through the second transmitting port and the light passing through the second receiving port are parallel.

3. The electrode cap testing device according to claim 2, characterized in that, Both the first detection head and the second detection head have receiving grooves. The first channel passes through the receiving groove of the first detection head and connects to the first electrode cap. The second channel passes through the second detection head and connects to the second electrode cap. The receiving groove is used to position the first electrode cap and the second electrode cap.

4. The electrode cap testing device according to claim 2, characterized in that, A waterproof column is formed on the side of the second detection head near the fiber optic sensor. The detection assembly also includes a sealing gasket, which is disposed between the first detection head and the fiber optic sensor. Both the waterproof column and the sealing gasket are used to prevent external water from entering between the first detection head and the second detection head.

5. The electrode cap testing device according to claim 2, characterized in that, The first detection head includes a first mounting hole, and the second detection head includes a second mounting hole. The first mounting hole is used to cooperate with the second mounting hole to achieve the positioning and installation of the first detection head and the second detection head.

6. The electrode cap testing device according to claim 1, characterized in that, The electrode cap detection device also includes an optical fiber amplifier, which is used to amplify the optical signal received by the receiving port and compare the amount of reflection with the set value.

7. The electrode cap testing device according to claim 6, characterized in that, The electrode cap testing device further includes a fixing base, which includes a first accommodating cavity and a second accommodating cavity that are connected. The first accommodating cavity is used to house the optical fiber amplifier, and the second accommodating cavity is used to house the testing component.

8. The electrode cap testing device according to claim 7, characterized in that, The electrode cap testing device also includes a dust cover, which is slidably fitted onto the fixed base and can slide along the length of the fixed base to cover or expose the testing component.

9. The electrode cap testing device according to claim 8, characterized in that, The electrode cap testing device also includes a guide block and an elastic element disposed on the guide block. The guide block is disposed on the fixed base and connected to the dust cover through the elastic element.

10. The electrode cap testing device according to claim 7, characterized in that, The electrode cap testing device further includes a floating unit, which is disposed on the frame and can move vertically relative to the frame. The fixed base is disposed on the floating unit, and the floating unit enables the fixed base to drive the testing component to have elastic margin in at least two vertical directions relative to the frame.

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