WO2023029562A1 - 钢丝帘布缺陷检测*** - Google Patents
钢丝帘布缺陷检测*** Download PDFInfo
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- WO2023029562A1 WO2023029562A1 PCT/CN2022/091911 CN2022091911W WO2023029562A1 WO 2023029562 A1 WO2023029562 A1 WO 2023029562A1 CN 2022091911 W CN2022091911 W CN 2022091911W WO 2023029562 A1 WO2023029562 A1 WO 2023029562A1
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- Prior art keywords
- steel cord
- magnetic
- permanent magnet
- magnetic field
- signal
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- 238000001514 detection method Methods 0.000 title claims abstract description 79
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- 239000000696 magnetic material Substances 0.000 description 2
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- 238000005299 abrasion Methods 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
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- 230000009286 beneficial effect Effects 0.000 description 1
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- 229910052742 iron Inorganic materials 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
- G01N27/83—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws by investigating stray magnetic fields
Definitions
- the present application relates to the field of industrial non-destructive testing, in particular to a detection system capable of generating and detecting magnetic field images of steel cords.
- Steel cord is an important part of truck tires. It is composed of an outer rubber layer and steel cords wrapped in the rubber layer at equal intervals. As a belt layer of truck tires, it provides important support for strengthening the structural strength and bearing capacity of truck tires. During the manufacturing process of steel cord, due to the influence of production equipment and process flow, the steel wires in the steel cord may have uneven distribution such as bending, dislocation, disconnection, crossing, etc. If the distribution of steel wires in the steel cord cannot be detected in real time, then It will have an adverse effect on the quality of the steel cord, and directly affect the performance and safety of the truck tire.
- the traditional defect detection technology for steel cord is the non-destructive detection method based on X-rays. This method is gradually replaced by more economical, safe and convenient technical solutions due to high equipment costs and physical harm to operators.
- the magnetic field detection unit used is composed of ordinary magnetic heads and coils, and its volume is often much larger than the arrangement period of the steel wires in the steel cord.
- the detected magnetic field changes are the result of the superposition of magnetic field changes caused by multiple steel wires, making the detection results
- the accuracy is not high, and there are problems such as missed detection and wrong detection. Additional processing steps for missed detection and wrong detection need to be set, which is not conducive to real-time detection of steel cord defects.
- the existing steel cord defect detection technology based on magnetic field changes can only detect whether the steel wires are evenly spaced along the moving direction based on the analysis of the periodic changes in the magnetic field, and cannot detect the bending, misalignment, and disconnection of the steel wires in two-dimensional space. , Crossover and other defects are detected.
- the purpose of the present application is to provide a system capable of accurately generating magnetic image signals of steel cords in real time and detecting defects of the steel cords according to the magnetic image signals.
- a steel cord defect detection system used to generate a magnetic image signal of the steel cord and detect defects of the steel cord according to the magnetic image signal, including a limiting device for limiting the steel cord,
- the magnetic image acquisition device is used to generate the magnetic image signal of the steel cord, and the magnetic image detection device is used to detect the defects of the steel cord according to the magnetic image signal;
- the limit wheels on both sides of the steel cord, the number of the limit wheels on each side of the steel cord is not less than two and are distributed at intervals along the moving direction of the steel cord;
- the magnetic image acquisition The device includes a magnetic field unit, a magnetic sensor module and a signal processing unit;
- the magnetic field unit is used to generate a background magnetic field, including a first permanent magnet module and a second permanent magnet module oppositely arranged on both sides of the steel cord,
- the line connecting the first permanent magnet module and the second permanent magnet module is perpendicular to the surface of the steel cord, and the background magnetic field includes The magnetic lines of force passing through the steel cord vertically between the modules;
- the distance between the edge of the limiting wheel facing the side of the steel cord and the steel cord is less than 5mm.
- the distance between the surface of the first permanent magnet module facing the steel cord and the steel cord is greater than the distance between the edge of the limiting wheel facing the steel cord and the steel cord;
- the distance between the surface of the second permanent magnet module facing the side of the steel cord and the steel cord is greater than the distance between the edge of the limiting wheel facing the side of the steel cord and the steel cord.
- the first permanent magnet module includes a permanent magnet or a plurality of permanent magnets arranged at intervals along a direction perpendicular to the moving direction of the steel cord;
- the second permanent magnet module includes a permanent magnet or a plurality of permanent magnets Two permanent magnets are arranged at intervals along the direction perpendicular to the moving direction of the steel cord.
- the first permanent magnet module further includes a first magnetically conductive plate, and the first magnetically conductive plate is arranged on the surface of the first permanent magnet module facing the side of the steel cord;
- the second The permanent magnet module also includes a second magnetically conductive plate, and the second magnetically conductive plate is arranged on the surface of the second permanent magnet module facing the side of the steel cord; the first magnetically conductive plate, the second magnetically conductive plate
- the magnetic plate is made of magnetically permeable material.
- the magnetic sensor module includes: a plurality of magnetic sensitive elements arranged at intervals along a direction perpendicular to the moving direction of the steel cord, for acquiring and outputting the magnetic field of the steel cord at the position of the magnetic sensitive element signal, the magnetic field signal of the steel cord at the position of the magnetic sensitive element is an electrical signal;
- the control chip includes a plurality of input terminals and an output terminal, and the plurality of input terminals correspond to the plurality of magnetic sensitive elements one by one The output end is used to output the magnetic field signal of the steel cord, and the magnetic field signal of the steel cord is a serial electrical signal.
- the magnetic sensor module is arranged between the connection line of the first permanent magnet module and the second permanent magnet module, and the surface of the magnetic sensor module facing the side of the steel cord The distance from the steel cord is greater than the distance between the edge of the limiting wheel on the side facing the steel cord and the steel cord.
- the signal processing unit includes: an AD conversion module, connected to the control chip, for converting the magnetic field signal of the steel cord into a digital magnetic field signal of the steel cord; a data processing module, connected with the AD The conversion module is connected to process the digital magnetic field signal of the steel cord to generate the magnetic image signal of the steel cord; and the data sending module is used to send the magnetic image signal of the steel cord.
- the magnetic image detection device includes: a defect detection unit, configured to generate a defect detection result of the steel cord according to the magnetic image signal of the steel cord, and the defect detection result includes defect type and defect location information;
- a display unit configured to display the magnetic image signal of the steel cord and the defect detection result of the steel cord;
- a calculation unit configured to determine defect mark information according to the defect detection result of the steel cord and the moving speed of the steel cord , the defect marking information includes marking position information and marking trigger time; an execution processing unit is used to mark a defect according to the defect marking information; an alarm unit is used to perform an abnormal alarm; and a main control unit communicates with the data transmission
- the module is connected to receive the magnetic image signal of the steel cord and control the defect detection unit, the display unit, the calculation unit, the execution processing unit and the alarm unit.
- the steel cord defect detection system further includes a first frame and a second frame; the first frame is used to insert and fix the first permanent magnet module; the second frame Used to place and fix the second permanent magnet module, the magnetic sensor module and the signal processing unit; the surfaces of the first frame and the second frame facing the side of the steel cord for the cover.
- the distribution of the magnetic force lines of the background magnetic field is more uniform, and the consistency of the direction of the magnetic force lines is good, especially in the vicinity of the steel cord, which can pass through the steel cord vertically , so that the periodically arranged steel wires of the steel cord can cut the magnetic force lines at a vertical angle, so that the change of the magnetic field caused by the movement of the steel wires is more obvious, and the signal-to-noise ratio of the magnetic field change is effectively improved.
- the magnetic sensor module is composed of multiple magnetic sensitive elements, which effectively increases the detection range, and converts the change signal of the background magnetic field obtained by multiple magnetic sensitive elements into a two-dimensional magnetic image signal of the steel cord, which can analyze the steel cord. Based on the one-dimensional periodic arrangement of wires, the ability to detect defects such as bending, staggering, disconnection, and crossing of steel cords on a two-dimensional plane is added.
- Fig. 1 is the electrical schematic diagram of the magnetic field signal obtained by the magnetic sensitive element
- Fig. 2 is a system composition block diagram of the steel cord magnetic image signal detection system of the embodiment of the present application
- Fig. 3 is an assembly perspective view of a preferred implementation manner of the embodiment of the present application.
- Fig. 4 is an assembly side view of a preferred embodiment of the embodiment of the present application.
- Fig. 5 is the distribution situation of the background magnetic field line of force of the embodiment of the present application.
- Fig. 6 is the distribution situation of the background magnetic field magnetic force line of an embodiment contrasted with the embodiment of the present application;
- Fig. 7 is the preferred embodiment of the first permanent magnet module of the embodiment of the present application.
- FIG. 8 is a perspective view of a magnetic sensor module and a signal processing unit in a preferred embodiment of the embodiment of the present application.
- FIG. 9 is an electrical schematic diagram of a magnetic sensor module according to an embodiment of the present application.
- FIG. 10 is an electrical schematic diagram of a magnetic sensor module in a preferred embodiment of the embodiment of the present application.
- Fig. 11 is a working flow chart of the signal processing unit of the embodiment of the present application.
- Fig. 12 is the magnetic image signal of the steel cord fabric generated by the signal processing unit of the embodiment of the present application.
- Fig. 13 is a working flow chart of the magnetic image detection device according to the embodiment of the present application.
- Fig. 14 is a schematic diagram of marking a defect position on a magnetic image signal of a steel cord according to an embodiment of the present application.
- 11 limit wheel 211 first permanent magnet module, 212 second permanent magnet module, 213 first magnetic plate, 214 second magnetic plate, 221 magnetic sensor module, 2210 magnetic sensitive element, 2211 control chip, 23 signal processing unit, 41 steel cord, 51 first frame body, 52 second frame body, 53 cover plate, 61 first circuit substrate, 62 second circuit substrate, 70 signal connection line.
- Figure 1 is the electrical schematic diagram of the magnetic field signal obtained by the magnetic sensitive element.
- the magnetic sensitive element is a component that can sense the magnetic field and convert the magnetic field signal into an electrical signal for output, including a series magneto-sensitive resistor and a reference resistance, wherein the resistance value Rs of the magneto-sensitive resistor changes with the change of the induced magnetic field, and the resistance value Rf of the reference resistance is a constant value.
- the output voltage signal Vo is A magnetic field signal that reflects changes in the location of each magnetic sensor.
- a plurality of magnetic sensitive elements are generally arranged at intervals along a preset direction, and the magnetic field signals output by a plurality of magnetic sensitive elements are processed in parallel to serial, and the serial output in the form of a magnetic field signal.
- Fig. 2 is a system block diagram of the embodiment of the present application
- Fig. 3 is an assembly perspective view of a preferred implementation of the embodiment of the present application (the magnetic image detection device is not included in the figure)
- Fig. 4 is a preferred embodiment of the present application The assembled side view of the embodiment of (the magnetic image detection device is not included in the figure).
- the embodiment of the present application provides a steel cord defect detection system, which is used to generate a magnetic image signal of the steel cord and detect the defect of the steel cord according to the magnetic image signal, including a limit device, Used to limit the steel cord 41, the magnetic image acquisition device is used to generate the magnetic image signal of the steel cord 41, and the magnetic image detection device is used to detect the defect of the steel cord according to the magnetic image signal.
- a limit device Used to limit the steel cord 41, the magnetic image acquisition device is used to generate the magnetic image signal of the steel cord 41, and the magnetic image detection device is used to detect the defect of the steel cord according to the magnetic image signal.
- the limit device includes limit wheels 11 oppositely arranged on both sides of the steel cord 41 (in order to clearly illustrate the embodiment of the application, the steel cord 41 is periodically distributed in the steel cord
- the number of limit wheels 11 located on each side of the steel cord 41 is not less than two and are distributed at intervals along the moving direction of the steel cord 41. Driven by the device, it moves in the direction shown by the dotted arrow, and the transmission device is well known to those skilled in the art, and will not be repeated here.
- the distance between the edge of the limiting wheel 11 facing the steel cord 41 and the steel cord 41 is less than 5mm, and by setting the distance between the edge of the limiting wheel 11 facing the steel cord 41 and the steel cord 41, the limiting wheel 11 The steel cord 41 is kept in a non-contact position instead of being pressed against the steel cord 41 , thereby effectively avoiding the abrasion of the surface of the steel cord 41 by the magnetic image acquisition device.
- the magnetic image acquisition device includes a magnetic field unit, a magnetic sensor module 221 and a signal processing unit 23 .
- the magnetic field unit is used to generate the background magnetic field, including the first permanent magnet module 211 and the second permanent magnet module 212 oppositely arranged on both sides of the steel cord 41, the first permanent magnet module 211 and the second permanent magnet module 212
- the connecting line between the two permanent magnet modules 212 is perpendicular to the surface of the steel cord 41
- the background magnetic field includes a magnetic field line between the first permanent magnet module 211 and the second permanent magnet module 212 passing through the steel cord 41 perpendicularly.
- the distance between the surface of the first permanent magnet module 211 facing the steel cord 41 and the steel cord 41 is greater than the distance between the edge of the limiting wheel 11 facing the steel cord 41 and the steel cord 41 ;
- the distance between the surface of the second permanent magnet module 212 facing the steel cord 41 and the steel cord 41 is greater than the distance between the edge of the limiting wheel 11 facing the steel cord 41 and the steel cord 41 .
- the first permanent magnet module 211 includes a permanent magnet or a plurality of permanent magnets arranged at intervals along a direction perpendicular to the moving direction of the steel cord;
- the second permanent magnet module 212 includes a permanent magnet or a plurality of permanent magnets along the Permanent magnets arranged at intervals in a direction perpendicular to the moving direction of the steel cord.
- the first permanent magnet module 211 also includes a first magnetically conductive plate 213, and the first magnetically conductive plate 213 is arranged on the surface of the first permanent magnet module 211 facing the steel cord 41;
- the second permanent magnet module 212 also includes a second magnetically conductive plate 214, and the second magnetically conductive plate 214 is arranged on the surface of the second permanent magnet module 212 facing the steel cord 41 side;
- the first magnetically conductive plate 213, the second magnetically conductive plate 213 Plate 214 is made of magnetically permeable material.
- the first magnetically permeable plate 213 and the second magnetically permeable plate 214 can be made of iron plate, ferrite plate, permalloy plate and/or silicon steel plate, etc., for The magnetic force lines of the background magnetic field generated by the first permanent magnet module 211 and the second permanent magnet module 212 are guided to make the distribution of intensity and direction more uniform.
- FIG. 5 shows the distribution of the magnetic force lines of the background magnetic field in the embodiment of the present application.
- FIG. 6 shows the distribution of the magnetic force lines of the background magnetic field when the permanent magnet module is only installed on the steel cord 41 side.
- Utilizing the arrangement of the magnetic field module in the embodiment of the present application can make the distribution of the magnetic force lines of the background magnetic field more uniform and concentrated in the direction perpendicular to the direction of movement of the steel cord 41, so that the steel cords in the steel cord 41 can cut the magnetic force lines vertically , thereby greatly increasing the variation range of the background magnetic field when the steel cord 41 moves, and effectively improving the signal-to-noise ratio of the obtained magnetic field signal.
- the cross-sectional width of the first permanent magnet module 211 towards the side of the steel cord 41 is smaller than the distance between adjacent steel cords of the steel cord 41; Line spacing.
- the cross-sectional shape of the first permanent magnet module 211 can be set as a trapezoid that gradually shrinks toward the steel cord 41, and set it toward
- the cross-sectional width of one side of the steel cord 41 is smaller than the distance between adjacent steel cords
- the cross-sectional shape of the second permanent magnet module 212 is set to be rectangular, and its cross-sectional width is set to be smaller than the distance between adjacent steel cords of the steel cord 41 .
- the cross-sectional shape of the first permanent magnet module 211 may also be set as a wedge shape gradually shrinking toward the steel cord 41 or other gradually shrinking shapes.
- the cross-sectional width of the first permanent magnet module 211 and the second permanent magnet module 212 towards the side of the steel cord 41 is smaller than the distance between adjacent steel cords, and further setting the cross-section of the first permanent magnet module 211
- Signal interference makes the change signal of the background magnetic field acquired by the magnetic sensor more sensitive to the movement of the steel cord in the detection area, which can effectively improve the accuracy of the change signal of the background magnetic field acquired by the magnetic sensor.
- Fig. 8 is a perspective view of the magnetic sensor module 221 and the signal processing unit 23 of the embodiment of the present application (for a clearer description, the blocked part in the figure is shown with a dotted line), and Fig. 9 is a perspective view of the magnetic sensor module of the embodiment of the present application Electrical schematics.
- the magnetic sensor module 221 includes: a plurality of magnetic sensitive elements 2210 arranged at intervals along the direction perpendicular to the moving direction of the steel cord, used to obtain and output the steel cord 41
- the control chip 2211 includes a plurality of input terminals and an output terminal, and a plurality of input terminals and a plurality of magnetic sensitive components
- the elements 2210 are connected in one-to-one correspondence, and the output end is used to output the magnetic field signal of the steel cord 41, wherein the magnetic field signal of the steel cord 41 is a serial electrical signal.
- the magnetic sensor module 221 is arranged between the connecting line of the first permanent magnet module 211 and the second permanent magnet module 212, and the surface of the magnetic sensor module 221 facing the side of the steel cord 41 is in contact with the surface of the steel cord 41.
- the distance is greater than the distance between the edge of the limiting wheel 11 facing the side of the steel cord and the steel cord 41 .
- a plurality of magnetic sensitive elements 2210 are located in the background magnetic field, arranged at intervals in a direction perpendicular to the direction of motion of the steel cord 41, and the sensed steel wires
- the magnetic field signal of the curtain 41 at this position is output to the control chip 2211 through the signal connection line 70 in the form of an electric signal Vo.
- the 2211 also includes a clock signal terminal for receiving the clock signal CLK and a start signal terminal for receiving the start signal SI. After receiving the start signal SI, the control chip 2211 sequentially reads a plurality of magnetic sensors under the synchronization of the clock signal CLK.
- the magnetic field signal Vo obtained by the element 2210 is converted from parallel to serial processing to form a serial magnetic field signal Vout of the steel cord, and is output to the signal processing unit 23 through the output terminal.
- Fig. 10 is an electrical schematic diagram of another specific implementation of the magnetic image acquisition device of the embodiment of the present application.
- multiple magnetic sensor modules 221 can also be combined with the The movement direction of 41 is arranged and connected at intervals in the direction perpendicular to the movement direction. After receiving the start signal SI, multiple magnetic sensor modules output the magnetic field signal Vout of the steel cord to the signal processing unit 23 in sequence under the synchronization of the clock signal CLK.
- signal processing unit 23 comprises AD conversion module, is connected with control chip 2211, is used to convert the magnetic field signal of steel cord to the digital magnetic field signal of steel cord 41;
- Data processing module is connected with AD conversion module, uses The digital magnetic field signal of the steel cord 41 is processed to generate a magnetic image signal of the steel cord 41 ; and the data sending module is used for sending the magnetic image signal of the steel cord 41 .
- the AD conversion module may be an 8-bit analog-to-digital conversion chip, connected to the control chip 2211 through the signal connection line 70, and converts the magnetic field signal Vout of the serial steel cord 41 into The output interval is the digital magnetic field signal Dout of the serial steel cord 41 of 0-255 (total 256 levels); the AD conversion module can also be an analog-to-digital conversion chip with a higher number of digits, so as to divide the output interval more finely;
- the data processing module may include a clock signal interface, which converts the digital magnetic field signal Dout of the steel cord 41 into a magnetic image signal Dimage of the steel cord 41 under the synchronization of the clock signal CLK;
- the data sending module sends the magnetic image signal Dimage of the steel cord 41 to the magnetic image detection device in a wired or wireless manner.
- Fig. 12 shows the magnetic image signal generated by the signal processing unit in the specific implementation manner of the embodiment of the present application.
- a correction module may also be provided between the AD conversion module and the data processing module to correct the digital magnetic field signal Dout of the steel cord 41 .
- the steel cord defect detection system of the embodiment of the present application also includes a first frame body 51 and a second frame body 52, the first frame body 51 is used to insert and fix the first permanent magnet module 211; the second frame body 52 is used to insert and fix the second permanent magnet module 212, the magnetic sensor module 221 and the signal processing unit 23; the first frame body 51 and the second frame body 52 face the side of the steel cord 41
- the surface is a cover plate 53 .
- the first frame body 51 and the second frame body 52 are oppositely arranged on both sides of the steel cord 41; the first permanent magnet module 211 is fixedly placed in the first frame body 51 and the first magnetically permeable plate 213 is placed on the surface of the first permanent magnet module 211 facing the steel cord 41 side, and the second permanent magnet module 212 is fixedly placed in the second frame body 52 and the second magnetic plate 214 is placed on the surface of the second permanent magnet module 213 facing the steel cord 41; a plurality of magnetic sensitive elements 2210 and control chips 2211 are respectively packaged on one side of the first circuit substrate 61 facing the steel cord 41.
- the side and the side facing away from the steel cord 41, and a plurality of magnetic sensitive elements 2210 are placed between the connecting lines of the first permanent magnet module 211 and the second permanent magnet module 212, and the first circuit board 61 is fixed on the second In the second frame body 52 and located on the surface of the second magnetically conductive plate 214 facing the steel cord 41 side; the signal processing unit 23 is packaged on the second circuit substrate 62, and is connected with the control chip 2211 by a signal connection line 70 (not shown in FIG.
- the signal connection line 70 is shown), and the second circuit board 62 is fixed on the side of the second frame 52 away from the steel cord 41; the surface of the frame 51 and the frame 52 facing the steel cord 41 is a cover plate 53, and the cover The plate 53 is made of a material with high wear resistance, and is used to protect the signal magnetic sensor module 221 and the first magnetic field module 211 and prevent the steel cord 41 from being worn.
- Fig. 13 is a system block diagram of a magnetic image detection device.
- the magnetic image detection device includes a defect detection unit for generating a defect detection result of the steel cord 41 according to a magnetic image signal of the steel cord 41, and the defect detection result includes a defect type and location information of the defect; a display unit for displaying the magnetic image signal of the steel cord 41 and the defect detection result of the steel cord 41; a calculation unit for determining according to the defect detection result of the steel cord 41 and the moving speed of the steel cord 41 defect mark information, the defect mark information includes mark position information and mark trigger time; the execution processing unit is used to mark the defect according to the defect mark information; the alarm unit is used for abnormal alarm; and the main control unit is connected with the data sending module, It is used to receive the magnetic image signal of the steel cord 41 and control the defect detection unit, display unit, calculation unit, execution processing unit and alarm unit.
- the main control unit may be the main processor in a desktop computer or a notebook computer, by reading and running the control program in a storage device such as a hard disk or an optical disk, and the defect detection unit,
- the display unit, calculation unit, execution processing unit, and alarm unit communicate and control the above-mentioned units to execute their respective workflows.
- the main control unit receives the magnetic image signal Dimage sent by the data sending module of the signal processing unit 23 through a wired data interface or a wireless transmission data interface.
- the defect detection unit analyzes defects such as position deviation, bending, disconnection, and crossing of the periodically arranged steel cords contained therein, and generates defects Detection results, defect detection results include defect type and defect location information.
- the display unit displays magnetic image signals and defect detection results, and the display unit can be a monitor of a desktop computer, a screen of a notebook or a tablet computer.
- Fig. 14 shows the magnetic image signal of the steel cord 41 including the defect detection result displayed by the display unit in a specific implementation of the embodiment of the present application.
- the calculation unit obtains the defect detection result generated by the defect detection unit, and determines the defect mark information such as the mark position and mark trigger time required by the execution processing unit for defect mark according to the moving speed of the steel cord 41, and sends the above defect mark information to Execution processing unit.
- the execution processing unit can be a device such as a mechanical arm with a marking function, which can perform two-dimensional movement in the horizontal direction and move up and down in the vertical direction. After the execution processing unit receives the defect marking information, it will check the marking position to mark.
- the alarm unit issues an alarm when detecting a defect in the steel cord 41 through sound, light, image and other means.
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Abstract
一种钢丝帘布(41)缺陷检测***,包括限位装置,用于对钢丝帘布(41)进行限位,磁图像获取装置,用于获取钢丝帘布(41)的磁图像信号,以及磁图像检测装置,用于根据磁图像信号对所述钢丝帘布(41)的缺陷进行检测;限位装置包括对向设置于钢丝帘布(41)两侧的多个限位轮(11),磁图像获取装置包括磁场单元、磁传感器模组(221)和信号处理单元(23),磁场单元包括对向设置于钢丝帘布(41)两侧的第一永磁体模组(211)和第二永磁体模组(212)。检测***能够基于穿过背景磁场的钢丝帘布(41)引起背景磁场的变化情况生成钢丝帘布(41)的磁图像信号并对磁图像信号进行检测。
Description
本申请涉及工业无损检测领域,具体涉及一种能够生成并检测钢丝帘布的磁场图像的检测***。
钢丝帘布是载重轮胎的重要组成部分,由外层的橡胶层和包裹在橡胶层内部等间隔排列的钢丝帘线构成,作为载重轮胎束带层为加强载重轮胎的结构强度及承载提供重要支撑。钢丝帘布的制造过程中,由于生产设备和工艺流程的影响,钢丝帘布中的钢丝可能存在弯曲、错位、断开、交叉等分布不均现象,如不能实时检测钢丝帘布中钢丝的分布情况,则将对钢丝帘布的质量产生不利影响,并直接影响到载重轮胎的性能及安全性。
传统的对钢丝帘布进行缺陷检测的技术为基于X射线的无损检测方法,该方法因设备成本高及对操作人员身体具有伤害,因此逐渐被更加经济、安全、方便的技术方案所代替。
一种代替的技术方案为基于磁场的钢丝帘布缺陷检测技术,利用钢丝相对于磁场的运动所导致的磁场变化来检测钢丝帘布的缺陷。但现有的基于磁场的钢丝帘布缺陷检测装置,普遍存在以下问题:
1、所使用的磁场检测单元由普通的磁头与线圈构成,其体积往往远大于钢丝帘布中钢丝的排列周期,所检测到的磁场变化为多条钢丝引起的磁场变化叠加的结果,使得检测结果精度不高,存在漏检、错检等问题,需要额外设置对于漏检、错检的处理步骤,不利于对钢丝帘布缺陷进行实时检测。
2、由于所使用的磁场检测边缘磁力线分布不均且方向散乱,因此容易受外部磁干扰影响,对检测结果精度影响较大,容易出现误报等问题。
3、现有的基于磁场变化的钢丝帘线缺陷检测技术只能根据分析磁场周期性变化检测钢丝沿运动方向的排列间隔是否均匀,无法对钢丝在二维空间上存在的弯曲、错位、断开、交叉等缺陷进行检测。
为解决以上钢丝帘布缺陷检测技术存在的问题,特提出本申请。
发明内容
本申请目的在于提供一种能够实时、精确地生成钢丝帘布的磁图像信号并根据所述磁图像信号对钢丝帘布的缺陷进行检测的***。
本申请可以通过以下技术方案实现:
一种钢丝帘布缺陷检测***,用于生成钢丝帘布的磁图像信号并根据所述磁图像信号对所述钢丝帘布的缺陷进行检测,包括限位装置,用于对所述钢丝帘布进行限位,磁图像获取装置,用于生成所述钢丝帘布的磁图像信号,以及磁图像检测装置,用于根据所述磁图像信号对所述钢丝帘布的缺陷进行检测;所述限位装置包括对向设置于所述钢丝帘布两侧的限位轮,位于所述钢丝帘布每 一侧的所述限位轮的数量不少于两个且沿所述钢丝帘布的运动方向间隔分布;所述磁图像获取装置包括磁场单元、磁传感器模组和信号处理单元;所述磁场单元用于生成背景磁场,包括对向设置于所述钢丝帘布两侧的第一永磁体模组和第二永磁体模组,所述第一永磁体模组和所述第二永磁体模组的连线垂直于所述钢丝帘布的表面,所述背景磁场包括位于所述第一永磁体模组和所述第二永磁体模组之间的垂直穿过所述钢丝帘布的磁力线;所述磁传感器模组用于获取并输出所述钢丝帘布的磁场信号;所述信号处理单元用于根据所述钢丝帘布的磁场信号生成所述钢丝帘布的磁图像信号。
进一步地,所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离小于5mm。
进一步地,所述第一永磁体模组朝向所述钢丝帘布一侧的表面与所述钢丝帘布的距离大于所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离;所述第二永磁体模组朝向所述钢丝帘布一侧的表面与所述钢丝帘布的距离大于所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离。
进一步地,所述第一永磁体模组包括一个永磁体或多个沿与所述钢丝帘布的运动方向垂直的方向间隔排列的永磁体;所述第二永磁体模组包括一个永磁体或多个沿与所述钢丝帘布的运动方向垂直的方向间隔排列的永磁体。
优选地,所述第一永磁体模组还包括第一导磁板,所述第一导磁板设置于所述第一永磁体模组朝向所述钢丝帘布一侧的表面;所述第二永磁体模组还包括第二导磁板,所述第二导磁板设置于所述第二永磁体模组朝向所述钢丝帘布一侧的表面;所述第一导磁板、第二导磁板由导磁材料制成。
进一步地,所述磁传感器模组包括:沿与所述钢丝帘布的运动方向垂直的方向间隔排列的多个磁敏元件,用于获取并输出所述钢丝帘布在所述磁敏元件位置的磁场信号,所述钢丝帘布在所述磁敏元件位置的磁场信号为电信号;控制芯片,包括多个输入端和一个输出端,所述多个输入端与所述多个磁敏元件一一对应地连接,所述输出端用于输出所述钢丝帘布的磁场信号,所述钢丝帘布的磁场信号为串行的电信号。
进一步地,所述磁传感器模组设置于所述第一永磁体模组和所述第二永磁体模组的连线之间,并且所述磁传感器模组朝向所述钢丝帘布一侧的表面与所述钢丝帘布的距离大于所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离。
进一步地,所述信号处理单元包括:AD转换模块,与所述控制芯片连接,用于将所述钢丝帘布的磁场信号转换为所述钢丝帘布的数字磁场信号;数据处理模块,与所述AD转换模块连接,用于对所述钢丝帘布的数字磁场信号进行处理,生成所述钢丝帘布的磁图像信号;以及数据发送模块,用于发送所述钢丝帘布的磁图像信号。
进一步地,所述磁图像检测装置包括:缺陷检测单元,用于根据所述钢丝帘布的磁图像信号生成所述钢丝帘布的缺陷检测结果,所述缺陷检测结果包括缺陷类型及缺陷的位置信息;显示单元,用于显示所述钢丝帘布的磁图像信号以及所述钢丝帘布的缺陷检测结果;计算单元,用于根据所述钢丝帘布的缺陷检测结果及所述钢丝帘布的运动速度确定缺陷标记信息,所述缺陷标记信息包括标记位置信息及标记触发时间;执行处理单元,用于根据所述缺陷标记信息进行缺陷标记;报警单元,用于进行异常报警;以及主控制单元,与所述数据发送模块连接,用于接收所述钢丝帘布的磁图像信号并控制所述缺陷检测单元、所述显示单元、所述计算单元、所述执行处理单元和所述报警单元。
优选地,所述钢丝帘布缺陷检测***还还包括第一框体和第二框体;所述第一框体用于置入并固定所述第一永磁体模组;所述第二框体用于置入并固定所述第二永磁体模组、所述磁传感器模组和所述信号处理单元;所述第一框体和所述第二框体朝向所述钢丝帘布一侧的表面为盖板。
本申请的实施例提供的一种钢丝帘布磁图像信号检测***至少具有以下有益效果:
1、通过对向设置的第一永磁体模组和第二永磁体模组,使得背景磁场的磁力线分布更加均匀,磁力线方向的一致性好,尤其是在钢丝帘布附近能够垂直地穿过钢丝帘布,使得所述钢丝帘布的周期性排列的钢丝能够以垂直的角度切割磁力线,从而使钢丝运动导致的磁场的变化更加明显,有效地提高了磁场变化的信噪比。
2、设置与钢丝帘布具有一定距离的限位轮,在保证钢丝帘布与磁场获取装置不发生接触的情况下,使钢丝帘布在检测位置具有一定的运动空间,此时由于磁力线为均匀且垂直地穿过钢丝帘布平面,因此所检测到的磁场变化信号精度不变,而限位轮并不压紧钢丝帘布,可以有效地避免对钢丝帘布表面造成的磨损。
3、磁传感器模组由多个磁敏元件构成,有效地增加了检测幅面,将多个磁敏元件获取的背景磁场的变化信号转换为钢丝帘布的二维磁图像信号,能够在分析钢丝帘线一维周期排列情况的基础上,增加了对于钢丝帘线在二维平面上的弯曲、错开、断开、交叉等缺陷进行检测的能力。
图1为磁敏元件获取磁场信号的电气原理图;
图2为本申请实施例的钢丝帘布磁图像信号检测***的***组成框图;
图3为本申请实施例的一种优选的实施方式的装配立体图;
图4为本申请实施例的一种优选的实施方式的装配侧视图;
图5为本申请实施例的背景磁场磁力线的分布情况;
图6为与本申请的实施例对比的一种实施方式的背景磁场磁力线的分布情况;
图7为本申请实施例的第一永磁体模组的优选的实施方式;
图8为本申请实施例的一种优选的实施方式的磁传感器模组和信号处理单元的立体图;
图9为本申请实施例的磁传感器模组的电气原理图;
图10为本申请实施例的一种优选的实施方式的磁传感器模组的电气原理图;
图11为本申请实施例的信号处理单元的工作流程图;
图12为本申请实施例的信号处理单元生成的钢丝帘布的磁图像信号;
图13为本申请实施例的磁图像检测装置的工作流程图;
图14为本申请实施例的在钢丝帘布的磁图像信号上标示缺陷位置的示意图。
图中标号
11限位轮,211第一永磁体模组,212第二永磁体模组,213第一导磁板,214第二导磁板,221磁传感器模组,2210磁敏元件,2211控制芯片,23信号处理单元,41钢丝帘布,51第一框体,52第二框体,53盖板,61第一线路基板,62第二线路基板,70信号连接线。
以下,基于优选的实施方式并参照附图对本申请进行进一步说明。
此外,为了方便理解,放大(厚)或者缩小(薄)了图纸上的各种构件,但这种做法不是为了限制本申请的保护范围。
单数形式的词汇也包括复数含义,反之亦然。
在本申请实施例中的描述中,需要说明的是,若出现术语“上”、“下”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系,或者是本申请的实施例使用时惯常摆放的方位或位置关系,仅是为了便于描述本申请和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本申请的限制。此外,本申请的描述中,为了区分不同的单元,本说明书上用了第一、第二等词汇,但这些不会受到制造的顺序限制,也不能理解为指示或暗示相对重要性,其在本申请的实施例的详细说明与权利要求书上,其名称可能会不同。
本说明书中词汇是为了说明本申请的实施例而使用的,但不是试图要限制本申请。还需要说明的是,除非另有明确的规定和限定,若出现术语“设置”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,可以是直接相连,也可以通过中间媒介间接连接,可以是两个元件内部的连通。对于本领域的技术人员而言,可以具体理解上述属于在本申请中的具体含义。
为更好地说明本申请实施例的技术方案,我们首先结合图1对磁敏元件获取磁场信号的原理进行介绍。
图1是磁敏元件获取磁场信号的电气原理图,如图1所示,磁敏元件是一种能够感应磁场并将磁场信号转换为电信号进行输出的元件,包含串联的磁敏电阻和基准电阻,其中,磁敏电阻的阻值Rs随感应到的磁场的变化而变化,基准电阻的阻值Rf为恒定值。
当需要获取磁场信号时,将磁敏元件置于背景磁场中,并如图1所示,向磁敏元件一端施加电压VDD,另一端接地,同时从磁敏电阻与基准电阻之间引出输出电压Vo。此时磁敏电阻的阻值Rs即为与背景磁场对应的阻值,根据分压原理,Vo=VDD*Rf/(Rf+Rs),输出的电压信号Vo即为反映背景磁场的信号。
当含有磁性材料的物体接近并进入背景磁场时,磁性材料的运动将引起背景磁场的变化,进而引起Rs的变化,并进一步引起输出的电压信号Vo的变化,此时的输出电压信号Vo即为反映每个磁敏元件所在位置的变化的磁场信号。
在实际的制造使用中,为获取宽幅的磁场信号,一般将多个磁敏元件沿预设方向间隔排列,并将多个磁敏元件输出的磁场信号进行并行转串行处理,以串行的磁场信号的形式进行输出。
以下结合图2至图14详细介绍本申请实施例的具体实施方案。
图2为本申请实施例的***框图,图3为本申请实施例的一种优选的实施方式的装配立体图(图中不包括磁图像检测装置),图4为本申请实施例的一种优选的实施方式的装配侧视图(图中不包括磁图像检测装置)。
如图2至图4所示,本申请的实施例提供一种钢丝帘布缺陷检测***,用于生成钢丝帘布的磁图像信号并根据磁图像信号对钢丝帘布的缺陷进行检测,包括限位装置,用于对钢丝帘布41进行限位,磁图像获取装置,用于生成钢丝帘布41的磁图像信号,以及磁图像检测装置,用于根据磁图像信号对钢丝帘布的缺陷进行检测。
以下,结合图3、图4详细说明本申请实施例的限位装置的具体实施方式。
如图3、图4所示,限位装置包括对向设置于钢丝帘布41两侧的限位轮11(为清楚说明本申请的实施例,钢丝帘布41以周期性分布于钢丝帘布内的钢丝帘线表示),位于钢丝帘布41每一侧的限位轮11的数量不少于两个且沿钢丝帘布41的运动方向间隔分布,需要说明的是,图中钢丝帘布41在另外设置的传动装置的带动下沿虚线箭头所示的方向运动,传动装置为本领域技术人员所公知,在此不再赘述。
进一步地,限位轮11朝向钢丝帘布41一侧的边缘与钢丝帘布41的距离小于5mm,通过设置限位轮11朝向钢丝帘布41一侧的边缘与钢丝帘布41的距离,使限位轮11保持对钢丝帘布41不接触地限位,而并不是压紧钢丝帘布41,从而可以有效地避免磁图像获取装置对钢丝帘布41表面造成的磨损。
以下,结合图2至图11详细说明本申请实施例的磁图像获取装置的具体实现方式。
如图2至图4所示,磁图像获取装置包括磁场单元、磁传感器模组221和信号处理单元23。
如图4所示,磁场单元用于生成背景磁场,包括对向设置于钢丝帘布41两侧的第一永磁体模组211和第二永磁体模组212,第一永磁体模组211和第二永磁体模组212的连线垂直于钢丝帘布41的表面,背景磁场包括位于第一永磁体模组211和第二永磁体模组212之间的垂直穿过钢丝帘布41的磁力线。
进一步地,如图4所示,第一永磁体模组211朝向钢丝帘布41一侧的表面与钢丝帘布41的距离大于限位轮11朝向钢丝帘布41一侧的边缘与钢丝帘布41的距离;第二永磁体模组212朝向钢丝帘布41一侧的表面与钢丝帘布41的距离大于限位轮11朝向钢丝帘布41一侧的边缘与钢丝帘布41的距离。
进一步地,第一永磁体模组211包括一个永磁体或多个沿与所述钢丝帘布的运动方向垂直的方向间隔排列的永磁体;第二永磁体模组212包括一个永磁体或多个沿与所述钢丝帘布的运动方向垂直的方向间隔排列的永磁体。
优选地,如图4所示,第一永磁体模组211还包括第一导磁板213,第一导磁板213设置于第一永磁体模组211朝向钢丝帘布41一侧的表面;第二永磁体模组212还包括第二导磁板214,第二导磁板214设置于第二永磁体模组212朝向钢丝帘布41一侧的表面;第一导磁板213、第二导磁板214由导磁材料制成。
在本申请实施例的具体实施方式中,第一导磁板213和第二导磁板214可以由铁板、铁氧合金板、坡莫合金板和/或硅钢板等材料制成,用于对第一永磁体模组211和第二永磁体模组212产生的背景磁场的磁力线进行引导,使其强度及方向的分布更加均匀。
图5示出本申请实施例的背景磁场的磁力线的分布情况,作为对比,图6示出只在钢丝帘布41一侧设置永磁体模组时的背景磁场的磁力线分布情况。
对图5及图6进行比较,可以看出,由于在钢丝帘布41的两侧对向设置了第一永磁体模组211和第二永磁体模组212,其产生的背景磁场的磁力线更加集中地分布于第一永磁体模组211和第二永磁体模组212的连线上,且垂直于钢丝帘布41的运动平面。利用本申请实施例的磁场模组的设置方式,能够使得背景磁场的磁力线分布更加均匀并集中在与钢丝帘布41运动方向垂直的方向,从而使得钢丝帘布41内的钢丝帘线能够垂直地切割磁力线,从而大大增加了钢丝帘布41运动时背景磁场的变化幅度,有效地提高了获取的磁场信号的信噪比。
本申请实施例的技术方案由于背景磁场的磁力线集中在与钢丝帘布41运动方向垂直的方向,因此即使钢丝帘布41受磁场单元的磁吸力在与运动方向垂直的方向产生位移,对于获取的磁场信号精度的影响也比较小,同时通过将限位轮11设置为更接近钢丝帘布41,使得钢丝帘布41无法吸附在磁场单元上,在保证所获取的磁场信号的精度的基础上,又无需通过压紧钢丝帘布41的方式来进行限位,从而避免了对钢丝帘布41表面造成的损伤。
优选地,第一永磁体模组211朝向钢丝帘布41一侧的截面宽度小于钢丝帘布41的相邻钢丝帘线的间距;第二永磁体模组212的截面宽度小于钢丝帘布41相邻钢丝帘线的间距。
具体地,如图7所示,在本申请的实施例的一个优选的实施方式中,可以将第一永磁体模组211的截面形状设置为朝向钢丝帘布41逐渐收缩的梯形,并设置其朝向钢丝帘布41一侧的截面宽度小于相邻钢丝帘线的间距,将第二永磁体模组212的截面形状设置为矩形,并设置其截面宽度小于钢丝帘布41相邻钢丝帘线的间距。
在本申请实施例的其他实现方式中,也可以将第一永磁体模组211的截面形状设置为朝向钢丝帘布41逐渐收缩的楔形或其他逐渐收缩的形状。
通过将第一永磁体模组211和第二永磁体模组212朝向钢丝帘布41一侧的截面宽度设置为小于相邻钢丝帘线的间距,并进一步将第一永磁体模组211的截面设置为逐渐收缩的梯形或楔形,能够使得背景磁场的磁力线的分布集中于钢丝帘线的一个间隔周期内,可以大大地减少检测区域以外的钢丝帘线的运动对磁传感器所获取的背景磁场的变化信号的干扰,使得磁传感器获取的背景磁场的变化信号对于位于检测区域内的钢丝帘线的运动更加敏感,可以有效提高磁传感器获取的背景磁场的变化信号的精度。
图8为本申请实施例的磁传感器模组221和信号处理单元23的立体图(为更清楚地说明,图中被遮挡部分以虚线显示),图9为本申请实施例的磁传感器模组的电气原理图。
如图4、图8及图9所示,磁传感器模组221包括:沿与所述钢丝帘布的运动方向垂直的方向间隔排列的多个磁敏元件2210,用于获取并输出钢丝帘布41在磁敏元件2210位置的磁场信号,其中,钢丝帘布41在磁敏元件2210位置的磁场信号为电信号;控制芯片2211,包括多个输入端和一个输出端,多个输入端与多个磁敏元件2210一一对应地连接,输出端用于输出钢丝帘布41的磁场信号,其中,钢丝帘布41的磁场信号为串行的电信号。
进一步地,磁传感器模组221设置于第一永磁体模组211和第二永磁体模组212的连线之间,并且磁传感器模组221朝向钢丝帘布41一侧的表面与钢丝帘布41的距离大于限位轮11朝向钢丝帘布一侧的边缘与钢丝帘布41的距离。
在本申请实施例的具体实现方式中,如图8、图9所示,多个磁敏元件2210位于背景磁场中, 按照与钢丝帘布41的运动方向垂直的方向间隔排列,将感应到的钢丝帘布41在该位置的磁场信号以电信号Vo的形式通过信号连接线70输出到控制芯片2211,控制芯片2211包括多个输入端,用于输入多个磁敏元件2210的磁场信号Vo,控制芯片2211还包括用于接收时钟信号CLK的时钟信号端和用于接收启动信号SI的启动信号端,控制芯片2211在接收到启动信号SI后,在时钟信号CLK的同步下依次读取多个磁敏元件2210获取的磁场信号Vo,进行并行转串行处理,形成串行的钢丝帘布的磁场信号Vout,并通过输出端向信号处理单元23输出。
图10为本申请实施例的磁图像获取装置的另一种具体的实施方式的电气原理图,在该实施方式中,为了扩大检测幅面,还可以将多个磁传感器模组221沿与钢丝帘布41的运动方向垂直的方向间隔排列并连接,多个磁传感器模组在接收到启动信号SI后,在时钟信号CLK的同步下依次向信号处理单元23输出钢丝帘布的磁场信号Vout。
以下结合图11的本申请实施例的信号处理单元23的工作流程图,详细说明信号处理单元23的具体实施方式。
如图11所示,信号处理单元23包括AD转换模块,与控制芯片2211连接,用于将钢丝帘布的磁场信号转换为钢丝帘布41的数字磁场信号;数据处理模块,与AD转换模块连接,用于对钢丝帘布41的数字磁场信号进行处理,生成钢丝帘布41的磁图像信号;以及数据发送模块,用于发送所述钢丝帘布41的磁图像信号。
具体地,在本申请实施例的具体实现方式中,AD转换模块可以是8位模数转换芯片,通过信号连接线70与控制芯片2211连接,将串行的钢丝帘布41的磁场信号Vout转换为输出区间为0-255(共256级)的串行的钢丝帘布41的数字磁场信号Dout;AD转换模块也可以是更高位数的模数转换芯片,以对输出区间进行更细的划分;
数据处理模块可以包含时钟信号接口,在时钟信号CLK的同步下将钢丝帘布41的数字磁场信号Dout转换为钢丝帘布41的磁图像信号Dimage;
数据发送模块以有线或无线方式向磁图像检测装置发送钢丝帘布41的磁图像信号Dimage。
图12为本申请实施例的具体实施方式中,信号处理单元生成的磁图像信号。
在本申请实施例的优选的实施方式中,还可以在AD转换模块和数据处理模块之间设置校正模块,用于对钢丝帘布41的数字磁场信号Dout进行校正。
以下,结合图3至图5,对本申请实施例中磁图像获取装置的一种优选的实现方式进行介绍。
如图3至图5所示,本申请实施例的钢丝帘布缺陷检测***还包括第一框体51和第二框体52,第一框体51用于置入并固定第一永磁体模组211;第二框体52用于置入并固定第二永磁体模组212、磁传感器模组221和信号处理单元23;第一框体51和第二框体52朝向钢丝帘布41一侧的表面为盖板53。
具体地,如图5所示,在本申请实施例的一种优选的实施方式中,第一框体51与第二框体52对向设置于钢丝帘布41两侧;第一永磁体模组211固定置于第一框体51中且第一导磁板213置于第一永磁体模组211朝向钢丝帘布41一侧的表面,第二永磁体模组212固定置于第二框体52中且第二导磁板214置于第二永磁体模组213朝向钢丝帘布41一侧的表面;多个磁敏元件2210和控制芯片2211分别封装于第一线路基板61朝向钢丝帘布41的一侧和背向钢丝帘布41的一侧,且多个 磁敏元件2210置于第一永磁体模组211和第二永磁体模组212的连线之间,第一线路基板61固定置于第二框体52内且位于第二导磁板214朝向钢丝帘布41一侧的表面;信号处理单元23封装于第二线路基板62上,与控制芯片2211通过信号连接线70连接(图4中未示出信号连接线70),第二线路基板固62定置于第二框体52远离钢丝帘布41的一侧;框体51和框体52朝向钢丝帘布41一侧的表面为盖板53,盖板53采用耐磨性较高的材料制成,用于保护信号磁传感器模组221和第一磁场模组211,并防止对钢丝帘布41造成磨损。
以下,结合图13、图14详细说明本申请实施例的磁图像检测装置的具体实施方式。
图13为磁图像检测装置的***框图,如图13所示,磁图像检测装置包括缺陷检测单元,用于根据钢丝帘布41的磁图像信号生成钢丝帘布41的缺陷检测结果,缺陷检测结果包括缺陷类型及缺陷的位置信息;显示单元,用于显示钢丝帘布41的磁图像信号以及钢丝帘布41的缺陷检测结果;计算单元,用于根据钢丝帘布41的缺陷检测结果及钢丝帘布41的运动速度确定缺陷标记信息,缺陷标记信息包括标记位置信息及标记触发时间;执行处理单元,用于根据缺陷标记信息进行缺陷标记;报警单元,用于进行异常报警;以及主控制单元,与数据发送模块连接,用于接收钢丝帘布41的磁图像信号并控制缺陷检测单元、显示单元、计算单元、执行处理单元和报警单元。
在本申请实施例的一种具体实施方式中,主控制单元可以是台式电脑或笔记本电脑中的主处理器,通过读取并运行硬盘或光盘等存储装置中的控制程序,与缺陷检测单元、显示单元、计算单元、执行处理单元、报警单元进行通信并控制上述各单元执行各自的工作流程。
主控制单元通过有线数据接口或无线传输数据接口接收信号处理单元23的数据发送模块发送的磁图像信号Dimage。
缺陷检测单元根据以二维灰度图形式显示的钢丝帘布41的磁图像信号Dimage,分析其中包含的周期性排列的钢丝帘线存在的位置偏离、弯曲、断开、交叉等缺陷,并生成缺陷检测结果,缺陷检测结果包括缺陷类型及缺陷的位置信息。
显示单元显示磁图像信号及缺陷检测结果,显示单元可以是台式电脑显示器、笔记本或平板电脑的屏幕。图14为本申请实施例的一种具体实施方式中,显示单元所显示的包含缺陷检测结果的钢丝帘布41的磁图像信号。
计算单元获取缺陷检测单元所生成的缺陷检测结果,根据钢丝帘布41的运动速度,确定由执行处理单元进行缺陷标记所需要的标记位置及标记触发时间等缺陷标记信息,将上述缺陷标记信息发送到执行处理单元。
执行处理单元可以是带有标记功能的机械臂等设备,可以在水平方向进行二维运动并在竖直方向上进行上下移动,执行处理单元接收到缺陷标记信息后,在标记触发时间对标记位置进行标记。
报警单元通过声、光、图像等方式在检测到钢丝帘布41缺陷时进行报警。
以上对本申请的具体实施方式作了详细介绍,对于本技术领域的技术人员来说,在不脱离本申请原理的前提下,还可以对本申请进行若干改进和修饰,这些改进和修饰也属于本申请权利要求的保护范围。
Claims (10)
- 一种钢丝帘布缺陷检测***,用于生成钢丝帘布的磁图像信号并根据所述磁图像信号对所述钢丝帘布的缺陷进行检测,包括限位装置,用于对所述钢丝帘布进行限位,磁图像获取装置,用于生成所述钢丝帘布的磁图像信号,以及磁图像检测装置,用于根据所述磁图像信号对所述钢丝帘布的缺陷进行检测,其特征在于:所述限位装置包括对向设置于所述钢丝帘布两侧的限位轮,位于所述钢丝帘布每一侧的所述限位轮的数量不少于两个且沿所述钢丝帘布的运动方向间隔分布;所述磁图像获取装置包括磁场单元、磁传感器模组和信号处理单元;所述磁场单元用于生成背景磁场,包括对向设置于所述钢丝帘布两侧的第一永磁体模组和第二永磁体模组,所述第一永磁体模组和所述第二永磁体模组的连线垂直于所述钢丝帘布的表面,所述背景磁场包括位于所述第一永磁体模组和所述第二永磁体模组之间的垂直穿过所述钢丝帘布的磁力线;所述磁传感器模组用于获取并输出所述钢丝帘布的磁场信号;所述信号处理单元用于根据所述钢丝帘布的磁场信号生成所述钢丝帘布的磁图像信号。
- 如权利要求1所述的钢丝帘布缺陷检测***,其特征在于:所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离小于5mm。
- 如权利要求2所述的钢丝帘布缺陷检测***,其特征在于:所述第一永磁体模组朝向所述钢丝帘布一侧的表面与所述钢丝帘布的距离大于所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离;所述第二永磁体模组朝向所述钢丝帘布一侧的表面与所述钢丝帘布的距离大于所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离。
- 如权利要求3所述的钢丝帘布缺陷检测***,其特征在于:所述第一永磁体模组包括一个永磁体或多个沿与所述钢丝帘布的运动方向垂直的方向间隔排列的永磁体;所述第二永磁体模组包括一个永磁体或多个沿与所述钢丝帘布的运动方向垂直的方向间隔排列的永磁体。
- 如权利要求4所述的钢丝帘布缺陷检测***,其特征在于:所述第一永磁体模组还包括第一导磁板,所述第一导磁板设置于所述第一永磁体模组朝向所述钢丝帘布一侧的表面;所述第二永磁体模组还包括第二导磁板,所述第二导磁板设置于所述第二永磁体模组朝向所述钢丝帘布一侧的表面;所述第一导磁板、第二导磁板由导磁材料制成。
- 如权利要求1所述的钢丝帘布缺陷检测***,其特征在于,所述磁传感器模组包括:沿与所述钢丝帘布的运动方向垂直的方向间隔排列的多个磁敏元件,用于获取并输出所述钢丝帘布在所述磁敏元件位置的磁场信号,所述钢丝帘布在所述磁敏元件位置的磁场信号为电信号;控制芯片,包括多个输入端和一个输出端,所述多个输入端与所述多个磁敏元件一一对应地连接,所述输出端用于输出所述钢丝帘布的磁场信号,所述钢丝帘布的磁场信号为串行的电信号。
- 如权利要求6所述的钢丝帘布缺陷检测***,其特征在于:所述磁传感器模组设置于所述第一永磁体模组和所述第二永磁体模组的连线之间,并且所述磁传感器模组朝向所述钢丝帘布一侧的表面与所述钢丝帘布的距离大于所述限位轮朝向所述钢丝帘布一侧的边缘与所述钢丝帘布的距离。
- 如权利要求7所述的钢丝帘布缺陷检测***,其特征在于,所述信号处理单元包括:AD转换模块,与所述控制芯片连接,用于将所述钢丝帘布的磁场信号转换为所述钢丝帘布的数字磁场信号;数据处理模块,与所述AD转换模块连接,用于对所述钢丝帘布的数字磁场信号进行处理,生成所述钢丝帘布的磁图像信号;以及数据发送模块,用于发送所述钢丝帘布的磁图像信号。
- 如权利要求8所述的钢丝帘布缺陷检测***,其特征在于,所述磁图像检测装置包括:缺陷检测单元,用于根据所述钢丝帘布的磁图像信号生成所述钢丝帘布的缺陷检测结果,所述缺陷检测结果包括缺陷类型及缺陷的位置信息;显示单元,用于显示所述钢丝帘布的磁图像信号以及所述钢丝帘布的缺陷检测结果;计算单元,用于根据所述钢丝帘布的缺陷检测结果及所述钢丝帘布的运动速度确定缺陷标记信息,所述缺陷标记信息包括标记位置信息及标记触发时间;执行处理单元,用于根据所述缺陷标记信息进行缺陷标记;报警单元,用于进行异常报警;以及主控制单元,与所述数据发送模块连接,用于接收所述钢丝帘布的磁图像信号并控制所述缺陷检测单元、所述显示单元、所述计算单元、所述执行处理单元和所述报警单元。
- 如权利要求1至9中任一项所述的钢丝帘布缺陷检测***,其特征在于:所述钢丝帘布缺陷检测***还包括第一框体和第二框体;所述第一框体用于置入并固定所述第一永磁体模组;所述第二框体用于置入并固定所述第二永磁体模组、所述磁传感器模组和所述信号处理单元;所述第一框体和所述第二框体朝向所述钢丝帘布一侧的表面为盖板。
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