CN-121994707-A - Compact defect detection device for T-shaped material welding and use method

CN121994707ACN 121994707 ACN121994707 ACN 121994707ACN-121994707-A

Abstract

The invention particularly relates to a compact defect detection device for T-shaped material welding and a use method thereof. The device comprises an expansion platform, a welding slag removing mechanism, a visual acquisition module, a defect identification mechanism and an Internet of things terminal device, wherein the welding slag removing mechanism, the visual acquisition module, the defect identification mechanism and the Internet of things terminal device are integrally arranged on the expansion platform, the expansion platform is fixedly connected with a door-type welding machine platform and synchronously moves along with the door-type welding machine platform, the welding slag removing mechanism is used for cleaning welding slag on the surface of a welding seam, the visual acquisition module is used for acquiring a welding seam image, the defect identification mechanism is used for carrying out code spraying marking on a defect position, and the Internet of things terminal device is used for image identification, defect positioning and control instruction issuing. The invention adopts a modularized compact design, integrates slag cleaning, image acquisition, defect identification and marking and remote monitoring of the Internet of things, has the advantages of high degree of automation, good detection precision, small space occupation, high response speed and the like, is suitable for online quality detection and marking of long and straight welding seams of a door type welding machine, and effectively improves the intelligent level of welding quality control.

Inventors

QIAN TIANLONG
ZHU ZHENG
Zou Dingfu
WANG XUEMIN
ZHANG DESHENG
GAO MING
Xiao Jingchou
Zhuang yalong
SHEN YANG
LI ZHILIN

Assignees

扬州中远海运重工有限公司

Dates

Publication Date: 20260508
Application Date: 20260228

Claims (9)

1. The compact defect detection device for T-shaped material welding is characterized by comprising an expansion platform (5), a welding slag removing mechanism (1), a visual acquisition module (2), a defect identification mechanism (3) and an Internet of things terminal device (4) which are integrally arranged on the expansion platform (5), wherein the expansion platform (5) is fixedly connected with a door-type welding machine platform and synchronously moves along with the door-type welding machine, the welding slag removing mechanism (1) is used for physically cleaning the surface of a welding seam, the compact defect detection device comprises a hairbrush (11) and a first connecting plate (12), the first connecting plate (12) is fixed on the expansion platform (5), the hairbrush (11) is arranged on the first connecting plate (12) and keeps contact with the welding seam, the visual acquisition module (2) is in working connection with the welding slag removing mechanism (1) and is used for acquiring an image of the cleaned surface of the welding seam, the second connecting plate (21), an industrial camera (22), a light source (23) and a light source controller (24) are fixed on the platform (5), the industrial camera (22) and the light source (23) are fixed on the second connecting plate (21), and the industrial camera (21) is fixed on the industrial camera and the second connecting plate (21) and the Internet of things terminal device (4) are used for acquiring the image of the welding seam; The defect identification mechanism (3) comprises a code spraying machine (31), an ink box (32), a pressure regulating valve (33) and a power adapter (34), wherein the code spraying machine (31) and the ink box (32) are fixed on an expansion platform (5), the pressure regulating valve (33) is connected with an ink conveying system of the code spraying machine (31), the power adapter (34) is arranged in a protection box, the code spraying machine (31) marks the position of a welding defect according to an instruction of an Internet of things terminal device (4), the Internet of things terminal device (4) comprises an industrial personal computer (41), a lamplight serial server (42), the code spraying machine serial server (43) and a wireless network bridge (44), and the industrial personal computer (41) is fixed on the expansion platform (5) and is respectively in low-delay wireless communication with a vision acquisition module (2) and the defect identification mechanism (3) through the wireless network bridge (44) so as to receive image data, identify welding defects and generate identification control instructions.
2. Compact defect detection device for T-profile welding according to claim 1, characterized in that the brush (11) is arranged at an angle of 45 ° to the direction of the weld.
3. Compact defect detection device for T-profile welding according to claim 1, characterized in that the industrial camera (22) is low profile mounted, the light sources (23) are compactly arranged by means of adjustable brackets, the light source controller (24) being provided in a protective box.
4. Compact defect detection device for T-profile welding according to claim 1, characterized in that the industrial camera (22) is in communication connection with the industrial personal computer (41) via a wireless bridge (44), and the light source controller (24) is connected with the industrial personal computer (41) via a light string server (42) for dynamically adjusting the intensity of the light source (23).
5. The compact defect detection device for T-profile welding according to claim 1, wherein the code spraying machine (31) establishes a communication connection with the industrial personal computer (41) through a code spraying machine serial server (43) for receiving instructions and spraying code to mark the positions of the welding seam defects.
6. Compact defect detection device for T-profile welding according to claim 1, characterized in that the defect identification means (3) are kept at a minimum working distance from the vision acquisition module (2) in order to achieve a fast response marking after identification of a welding defect.
7. The compact defect detection device for welding T-shaped materials according to claim 1, wherein the terminal equipment (4) of the internet of things adopts a centralized power supply and wireless networking mode, all modules are connected through wireless communication, the terminal equipment (4) of the internet of things establishes connection with a remote monitoring center through a wireless bridge (44), and a real-time defect image and marking data are uploaded to realize remote quality monitoring.
8. The compact defect detection device for welding T-shaped materials according to claim 1, wherein the welding slag removing mechanism (1), the vision collecting module (2), the defect marking mechanism (3) and the terminal equipment (4) of the internet of things are used in pairs and symmetrically arranged on expansion platforms (5) on two sides of a long and straight welding seam welding station to realize synchronous detection and marking of defects of double-side welding seams, and the expansion platforms (5) are provided with rollers which are in contact with the T-shaped materials.
9. A method of using a compact defect detection device for T-bar welding based on any one of claims 1 to 8, comprising the steps of: The method comprises the steps of S1, cleaning welding slag, enabling an expansion platform to synchronously move along with a portal welding machine after welding guns finish long and straight welding seams, enabling a hairbrush (11) of a welding slag cleaning mechanism (1) to follow and clean the surfaces of the long and straight welding seams, S2, enabling an image acquisition device (24) to dynamically adjust the intensity of a light source to optimize illumination environment, enabling an industrial camera (22) to continuously shoot images of the surfaces of the welding seams according to set frequency and transmit image data to an Internet of things terminal device (4), enabling a detection system to synchronously analyze and process the images, S3, enabling the Internet of things terminal device (4) to analyze the images and identify whether welding defects exist or not, enabling the Internet of things terminal device (4) to accurately calculate the distance between the defect positions and defect identification mechanisms (3) in real time if the image analysis identifies the welding defects, calculating the time of the defect identification mechanisms (3) to reach the defect positions according to the running speed of the portal welding machine, determining the optimal starting time of the defect identification mechanisms (3), and enabling the defect identification mechanisms (4) to carry out defect identification codes when the portal welding machine runs to the calculated trigger positions, and enabling the Internet of things terminal device (4) to send command codes to the Internet of things terminal device (3) to correspondingly spray the defect identification codes to the welding seam identification device (31).

Description

Compact defect detection device for T-shaped material welding and use method Technical Field The invention relates to the technical field of welding intellectualization technology and equipment, in particular to a compact defect detection device for T-shaped material welding and a use method thereof. Background In the fields of ship manufacturing, bridge construction, steel structure engineering and the like, the welding quality of a long straight welding line is directly related to structural safety and service life. At present, the door-type welding machine is widely applied to mass production of long straight welding seams due to high automation degree and high welding speed. However, surface defects such as air holes, slag inclusion, unfused and cracks are easy to generate in the welding process, and the existing detection means are mostly dependent on manual visual inspection or off-line spot inspection, so that the problems of low efficiency, high omission rate, poor instantaneity and the like exist. In recent years, weld joint detection equipment based on machine vision or X-rays is large in general size, complex in structure and difficult to integrate with compact equipment such as a door-type welding machine, and most of the equipment only has a detection function, lacks cleaning and marking closed-loop control capability, and cannot realize online operation of detection, namely marking. Therefore, there is a need for an integrated device for on-line defect detection and marking that is compact, highly integrated, and responsive to the operational mode of a door-type welding machine. Disclosure of Invention Aiming at the defects of the prior art, the invention provides a compact defect detection device for T-shaped welding and a use method thereof, which have the functions of automatic welding slag cleaning, dynamic acquisition of weld images, intelligent defect identification and accurate code spraying marking, remote monitoring of the Internet of things and the like, realize full-flow closed-loop control from cleaning to marking, and remarkably improve the automation level and reliability of welding quality detection. In order to achieve the above purpose, the invention adopts the following technical scheme: The compact defect detection device for T-shaped material welding comprises an expansion platform, and a welding slag removal mechanism, a visual acquisition module, a defect identification mechanism and an Internet of things terminal device which are integrally arranged on the expansion platform, wherein the expansion platform is fixedly connected with a door-type welding machine platform and synchronously moves along with the door-type welding machine; The welding slag removing mechanism is used for physically cleaning the surface of the welding seam and comprises a hairbrush and a first connecting plate, wherein the first connecting plate is fixed on the expansion platform; The visual acquisition module is in working connection with the welding slag removing mechanism and is used for acquiring the cleaned welding slag surface image, and the visual acquisition module comprises a second connecting plate, an industrial camera, a light source and a light source controller, wherein the second connecting plate is fixed on the expansion platform, the industrial camera and the light source are fixed on the second connecting plate, and the industrial camera acquires the welding slag image and outputs the welding slag image to the terminal equipment of the Internet of things; The defect identification mechanism comprises a code spraying machine, an ink box, a pressure regulating valve and a power adapter, wherein the code spraying machine and the ink box are fixed on the expansion platform, the pressure regulating valve is connected with an ink conveying system of the code spraying machine, the power adapter is arranged in the protection box, and the code spraying machine marks the position of the welding defect according to an instruction of the terminal equipment of the Internet of things; The Internet of things terminal equipment comprises an industrial personal computer, a lamplight serial port server, an ink jet printer serial port server and a wireless network bridge, wherein the industrial personal computer is fixed on an expansion platform, and is respectively in low-delay wireless communication with a vision acquisition module and a defect identification mechanism through the wireless network bridge and is used for receiving image data, identifying welding defects and generating identification control instructions. Preferably, the hairbrush is arranged at an included angle of 45 degrees with the direction of the welding line. Preferably, the industrial camera is installed in a low profile, the light sources are compactly distributed through the adjustable bracket, and the light source controller is arranged in the protection box. Preferably, the industrial camera is in communication connect