CN110095527A - Fluorescent magnetic particle flaw detection automation equipment and method on a kind of assembly line - Google Patents

Abstract

An automatic device and method for fluorescent magnetic particle flaw detection on an assembly line belongs to the technical field of automatic flaw detection. Including surface crack detection device (1), detection device support base (2), first power cable (3), first communication cable (4), laser range finder (5), laser range finder support base (6) , the second power cable (7), the second communication cable (8), the robot (9), the robot support base (10), the writing pen (11), the third power cable (12), the third communication cable (13) , industrial computer (14), industrial computer support seat (15), power cable (16). The advantage is that it solves the problem that it can only detect cracks with a width of more than mm order, but can't do anything about cracks with a width of sub-mm order. The automatic detection and automatic marking of cracks with a line width as low as sub-mm order is realized; moreover, it is easy to use and the cost is reasonable.

Description

An automatic device and method for fluorescent magnetic particle flaw detection on an assembly line

technical field

The invention belongs to the technical field of automatic flaw detection, and in particular provides an automatic device and method for fluorescent magnetic particle flaw detection on an assembly line.

Background technique

As a common method for detecting cracks on the surface of ferromagnetic workpieces, fluorescent magnetic particle inspection has been widely used in steel, chemical, aerospace, automobile, shipbuilding and other industries. The technological process of fluorescent magnetic particle flaw detection for workpieces on the assembly line is: place the workpiece on the roller table to keep the workpiece moving; when the workpiece passes through the fluorescent magnetic powder adding area, the fluorescent magnetic powder will be added to the surface of the workpiece; when the workpiece moves to the magnetic field application area, the magnetic field will Applied to the workpiece to enrich the magnetic powder around each crack; when the workpiece moves to the ultraviolet lamp irradiation area, if there is a crack on the surface of the workpiece, the crack will stand out from the background and be detected; add marks near the crack for subsequent operations.

There are mainly two types of fluorescent magnetic particle flaw detection technologies on the existing assembly line: semi-automatic and fully automatic.

For the semi-automatic method, the movement of the workpiece, the addition of magnetic powder, and the application of the magnetic field are carried out by manually operating electromechanical equipment. However, the determination of whether there is a crack on the surface and the marking of the crack (such as drawing a circle around the crack with chalk) are still carried out manually. This is more common in forged steel magnetic particle inspection factories.

For the fully automatic method (T Nishimine, O Tsuyama, T Tanaka, H Fujiwara. Automatic magnetic particle testing system for square billets [C], IEEE Industry Applications Conference, 1995, 2: 1585-1590.), the entire technological process runs automatically, especially The determination of the presence or absence of cracks on the surface and the marking of cracks are automatically performed by automatic equipment. Here, the method of judging and marking the crack is: during the continuous operation of the workpiece, use the camera to take pictures of the surface of the workpiece to obtain an image, then analyze the image, and judge whether there is a crack in it, if there is a crack, determine the position of the crack, and then drive the automatic The marking device marks the workpiece.

The advantage of the semi-automatic method is that on the basis of using electromechanical equipment to reduce human labor, it makes full use of human initiative. The disadvantage is that manual operation will be prone to fatigue due to numerous procedures, especially when the human eye sees tiny cracks in a dark room for a long time under weak light. It is easy to cause visual fatigue; in addition, the human body will receive a large amount of ultraviolet radiation if it is close to the ultraviolet lamp for a long time.

The advantage of the existing fully automatic method is to make full use of electromechanical to reduce people's labor, and the work efficiency is high, but the disadvantage is that the blurring of the image caused by the continuous movement of the workpiece will make it difficult to measure the tiny cracks, such as literature (T Nishimine, O Tsuyama, TTanaka, H Fujiwara.Automatic magnetic particle testing system for squarebillets[C],IEEE Industry Applications Conference,1995,2:1585-1590.) The running speed of the workpiece is 14m/min, and the resulting image blur width is N times of 0.23mm ( where N is the camera exposure time divided by the multiple of 1ms), considering that the fluorescence in the field is relatively dark, and the exposure time is at least a few ms to hundreds of ms, then this method can only detect cracks with a width of more than mm order, and for sub-mm order The width of the crack can do nothing.

Contents of the invention

The object of the present invention is to provide an automatic process device and method for fluorescent magnetic particle flaw detection; it solves the problem that it can only detect cracks with a width of more than mm order, but can't do anything about cracks with a width of sub-mm order. The automatic detection and automatic marking of cracks with a line width as low as sub-mm order is realized.

The main idea of the present invention is: realize the intermittent continuous operation of the workpiece on the roller table and ensure accurate positioning through the electromechanical device, that is, stop for a certain time after running a certain distance, and then stop for a certain time after running a certain distance, and so on; The crack detection device realizes clear photos of the workpiece surface during the stop period of the workpiece, and the accurate connection of the spatial positions between the photos, and at the same time enables the automatic marking device to accurately locate the crack for marking.

The device of the present invention includes a surface crack detection device 1, a detection device support base 2, a first power cable 3, a first communication cable 4, a laser rangefinder 5, a laser rangefinder support base 6, a second power supply cable 7, a first Two communication cables 8, a robot 9, a robot support base 10, a writing pen 11, a third power cable 12, a third communication cable 13, an industrial computer 14, an industrial computer support base 15, and a power cable 16.

The surface crack detection device 1 and the detection device support base 2 are connected through threads, and the surface crack detection device 1 is connected to a 250V10A AC power supply through a third power cable 12;

The laser range finder 5 and the laser range finder support base 6 are connected by bolts, and the laser range finder 5 is connected to a 250V10A AC power supply through a power cable 7;

The robot 9 and the robot support base 10 are connected by bolts; the end of the arm of the writing pen 11 and the robot 9 is fitted together through a round hole, and the robot 9 is connected to a 250V10A AC power supply through a third power cable 12;

The industrial computer 14 and the industrial computer support base 15 are connected by bolts; the industrial computer 14 is connected to the 250V10A AC power supply through the power cable 16;

The surface crack detection device 1, the laser range finder 5, and the robot 9 are respectively connected through the first communication cable 4, the second communication cable 8, the third communication cable 13 and the industrial computer 14; the industrial computer 14 runs measurement and control software to realize Automatic detection and marking of cracks on the workpiece surface.

Parts related to the present invention but not belonging to the present invention also include workpiece 17 , roller table 18 , workpiece magnetizing equipment 19 and workpiece cleaning equipment 20 . In the present invention, the workpiece magnetizing equipment and the workpiece surface cleaning equipment are in the automatic operation state by default.

The method described in the present invention is as follows:

1. Connect the device of the present invention according to the figure and place the workpiece 17 on the roller table 18, and perform the following adjustments and configurations:

(1) Make the roller table 18 drive the workpiece 17 to move from left to right until the right end of the workpiece 17 runs into the field of view of the surface crack detection device 1; adjust the position and attitude of the surface crack detection device 1 so that the lens optical axis It is perpendicular to the surface of the workpiece 17 and apart from a set distance (a fixed value of 0.3 to 0.8m), and the upper and lower edges of the photographs of the workpiece surface are all within the image; adjust the position and posture of the laser range finder 5 so that it The luminous point is located at the center of the workpiece end and can measure the distance of the workpiece 17 relative to the laser rangefinder 5; adjust the position and posture of the robot 9 so that the writing range of the writing pen 11 can cover the workpiece area captured by the camera;

(2) Make the roller table 18 drive the workpiece 17 to move left and right until the vertical line at the right end of the workpiece is just at the right edge of the camera field of view, and record the value of the laser rangefinder 5, which is the first measurement position of the workpiece. This parameter is an operating parameter of the industrial computer 14;

(3) mark on the workpiece corresponding to the left vertical edge of the camera, measure the distance between this mark and the right end of the workpiece, and the equal interval running distance of the workpiece, this parameter is another operating parameter of the industrial computer 14;

(4) Return the workpiece 17 to a place far away from the predetermined distance from the initial position;

2. Make the industrial computer 14 drive each device to run automatically as follows:

(1) Make the roller table 18 drive the workpiece 17 to run until the laser range finder 5 detects that the workpiece 17 moves to the first measurement position of the workpiece;

(2) Make the surface crack detection device 1 detect the crack on the workpiece surface corresponding to the first measuring position; if there is a crack, record the coordinates of the crack center and the radius of the covering circle of the crack;

(3) Make the roller table 18 drive the workpiece 17 to run until the laser rangefinder 5 detects that the workpiece 17 has run an equal distance;

(4) If a workpiece surface area containing cracks enters the drawing coverage of the robot 9, it is marked according to the corresponding crack coordinates and the coverage circle radius;

(5) Repeat steps (2) and (3) until all surfaces of the workpiece are measured and marked.

The invention has the advantages of convenient use and reasonable cost.

Description of drawings

Fig. 1 is a device structure diagram of the present invention. Among them: surface crack detection device 1, detection device support base 2, first power cable 3, first communication cable 4, laser range finder 5, laser range finder support base 6, second power supply cable 7, second communication cable 8. Robot 9, robot support base 10, writing pen 11, third power cable 12, third communication cable 13, industrial computer 14, industrial computer support base 15, power cable 16;

Fig. 2 is measurement and control software described in the present invention, and wherein circle is that the crack is marked, and the curve in the circle is the detected crack;

Detailed ways

The device of the present invention includes a surface crack detection device 1, a detection device support base 2, a first power cable 3, a first communication cable 4, a laser rangefinder 5, a laser rangefinder support base 6, a second power supply cable 7, a first Two communication cables 8, a robot 9, a robot support base 10, a writing pen 11, a third power cable 12, a third communication cable 13, an industrial computer 14, an industrial computer support base 15, and a power cable 16.

The surface crack detection device 1 and the detection device support base 2 are connected through threads, and the surface crack detection device 1 is connected to a 250V10A AC power supply through a third power cable 12;

The laser range finder 5 and the laser range finder support base 6 are connected by bolts, and the laser range finder 5 is connected to a 250V10A AC power supply through a power cable 7;

The robot 9 and the robot support base 10 are connected by bolts; the end of the arm of the writing pen 11 and the robot 9 is fitted together through a round hole, and the robot 9 is connected to a 250V10A AC power supply through a third power cable 12;

The industrial computer 14 and the industrial computer support base 15 are connected by bolts; the industrial computer 14 is connected to the 250V10A AC power supply through the power cable 16;

The surface crack detection device 1, the laser range finder 5, and the robot 9 are respectively connected through the first communication cable 4, the second communication cable 8, the third communication cable 13 and the industrial computer 14; the industrial computer 14 runs measurement and control software to realize Automatic detection and marking of cracks on the workpiece surface.

As shown in Figure 1, around the workpiece 17 and the roller table 18 and related devices, the device according to the present invention is prepared with various devices and connections. The workpiece 17 is forged steel with 2m rectangular cross-section, the cross-sectional size is 140mm*140mm, the roller table 18, the workpiece magnetic equipment 19, and the workpiece cleaning equipment 20 are equipped according to the existing equipment of the forged steel magnetic particle inspection factory;

Surface crack detection device 1 is selected according to "On-line detection device for fluorescent magnetic particle detection, 2018.05.09, China, ZL201820689967.9".

Robot 9 and writing pen 11 choose Snake-I mechanical arm and writing pen; laser rangefinder 5 chooses DT50 laser displacement sensor device; industrial computer chooses to have 2 gigabit network ports and 4-20mA signal acquisition unit For the Aicter 4U industrial computer, the communication cable 4 and communication cable 8 are industrial six-category network cables, the communication cable 13 is a 20m shielded cable with 3 cores and a core diameter of 1.8mm, and the power cable 3, power cable 8, and power cable 12 are industrial cables. Use 3m long three-core 250V10A AC power cable;

The device is adjusted and configured according to the method described in the present invention.

(1) Make the roller table 18 drive the workpiece 17 to move from left to right until the right end of the workpiece 17 runs into the field of view of the surface crack detection device 1; adjust the position and attitude of the surface crack detection device 1 so that the lens optical axis It is perpendicular to the surface of the workpiece 17 and is 0.5m apart, and the upper and lower edges of the photos taken on the workpiece surface fall within the image; adjust the position and posture of the laser rangefinder 5 so that its luminous point is located at the center of the workpiece end and can measure the workpiece 17 relative to the distance of the laser rangefinder 5; adjust the position and posture of the robot 9 so that the writing range of the writing pen 11 can cover the workpiece area photographed by the camera;

(3) Make the roller table 18 drive the workpiece 17 to move left and right until the vertical line at the right end of the workpiece is just at the right edge of the camera field of view, and record the value of the laser rangefinder 5 as 13.908m, which is the first measurement position of the workpiece . This parameter is an operating parameter of the industrial computer 14;

(4) Make a mark on the workpiece corresponding to the left vertical edge of the camera, and measure the distance between the mark and the right end of the workpiece to be 0.123m. parameter;

(5) Return the workpiece 17 to a place far away from the predetermined distance from the initial position;

2. Make the industrial computer 14 drive each device to run automatically as follows:

(1) Make the roller table 18 drive the workpiece 17 to run until the laser range finder 5 detects that the workpiece 17 moves to the first measurement position of the workpiece;

(2) Make the surface crack detection device 1 detect the crack on the workpiece surface corresponding to the first measuring position; if there is a crack, record the coordinates of the crack center and the radius of the covering circle of the crack;

(3) Make the roller table 18 drive the workpiece 17 to run until the laser rangefinder 5 detects that the workpiece 17 has run an equal distance;

(4) If a workpiece surface area containing cracks enters the drawing coverage of the robot 9, it is marked according to the corresponding crack coordinates and the coverage circle radius; the marking effect is shown in Figure 2.

(5) Repeat steps (2) and (3) until all surfaces of the workpiece are measured and marked.

Claims (2)

1. An automatic device for fluorescent magnetic particle flaw detection on an assembly line, characterized in that it includes a surface crack detection device (1), a detection device support seat (2), a first power cable (3), a first communication cable (4), a laser Range finder (5), laser range finder support base (6), second power cable (7), second communication cable (8), robot (9), robot support base (10), writing pen (11) , the third power cable (12), the third communication cable (13), the industrial computer (14), the industrial computer support seat (15), the power cable (16); The surface crack detection device (1) and the detection device support seat (2) are connected through threads, and the surface crack detection device (1) is connected to a 250V10A AC power supply through a power cable 2; The laser range finder (5) and the laser range finder support seat (6) are connected by bolts, and the laser range finder (5) is connected to the 250V10A AC power supply through the power cable (7); The robot (9) and the robot support base (10) are connected by bolts; the end of the arm of the writing pen (11) and the robot (9) is fitted together through a round hole, and the robot (9) is connected to the 250V10A by the third power cable (12). on AC power; The industrial computer (14) and the industrial computer support seat (15) are connected by bolts; the industrial computer (14) is connected to the 250V10A AC power supply through the power cable (16); The surface crack detection device (1), the laser range finder (5), and the robot (9) pass through the first communication cable (4), the second communication cable (8), the third communication cable (13) and the industrial computer (14) respectively. ) connection; measurement and control software runs on the industrial computer (14), so as to realize automatic detection and marking of workpiece surface cracks. 2. a method of operation of the device according to claim 1, characterized in that, the parameters of concrete steps and control are as follows: (1), the workpiece 17 is placed on the roller table 18, and the following adjustments and configurations are performed: 1) Make the roller table (18) drive the workpiece (17) to move from left to right until the right end of the workpiece (17) runs into the field of view of the surface crack detection device (1); adjust the surface crack detection device (1) The position and posture of the laser range finder (5) are adjusted so that the optical axis of the lens is perpendicular to the surface of the workpiece (17) and the distance is 0.3-0.8m, and the upper and lower edges of the photos taken on the surface of the workpiece fall within the image; adjust the position and posture of the laser rangefinder (5) , so that its luminous point is located at the center of the workpiece end and can measure the distance of the workpiece (17) relative to the laser range finder (5); adjust the position and posture of the robot (9) so that the writing range of the writing pen (11) can cover The area of the workpiece captured by the camera; 2) Make the roller table (18) drive the workpiece 17 to move left and right until the vertical line at the right end of the workpiece is just at the right edge of the camera's field of view, and record the value of the laser rangefinder (5), which is the first measurement position of the workpiece ; This parameter is a running parameter of industrial computer (14); 3) mark on the workpiece corresponding to the left vertical edge of the camera, measure the distance between this mark and the right end of the workpiece, the equal interval running distance of the workpiece, this parameter is another operating parameter of the industrial computer (14); 4) Return the workpiece (17) to a place far away from the predetermined distance from the initial position; (2), make industrial computer (14) drive each device to run automatically as follows: 1) Make the roller table (18) drive the workpiece (17) to run until the laser rangefinder (5) detects that the workpiece (17) moves to the first measurement position of the workpiece; 2) Make the surface crack detection device (1) detect the crack on the surface of the workpiece corresponding to the first measurement position; when there is a crack, record the coordinates of the crack center and the radius of the crack's coverage circle; 3) Make the roller table (18) drive the workpiece (17) to run until the laser rangefinder (5) detects that the workpiece (17) has run an equal distance; 4) When a workpiece surface area containing cracks enters the drawing coverage of the robot (9), it is marked according to the corresponding crack coordinates and the coverage circle radius; 5) Repeat steps 2) and 3) until all surfaces of the workpiece are measured and marked.