System and method for discriminating turning tool mark magnetic mark from false magnetic mark

文档序号:6191 发布日期:2021-09-17 浏览:53次 中文

1. A system for screening lathe tool marks from false magnetic marks, which is characterized by comprising:

the magnetic particle inspection equipment is used for carrying out surface magnetic particle inspection on a workpiece to be screened and has a view field range for displaying the accumulation morphology of magnetic marks;

the image acquisition equipment is over against the field range of the magnetic powder inspection equipment and is used for acquiring real images of the accumulation morphology of the magnetic marks;

the image processing module is used for extracting magnetic trace characteristics of the real image acquired by the image acquisition equipment to obtain a virtual image;

the magnetic mark evaluation method comprises the following steps that a database is stored, a plurality of discrimination images with magnetic mark accumulation appearances are stored in the database, and magnetic mark evaluation of the discrimination images is marked;

the AR module is used for mixing the virtual images and the discrimination images one by one to form mixed images;

the evaluation module is used for comparing the coincidence degree of the virtual image and the discriminated image in the mixed image, discriminating the magnetic traces in the real image according to the comparison result and outputting an evaluation result;

and the image marking module marks the evaluation result of the real image screened by the evaluation module and stores the marked real image into the database.

2. The system for screening magnetic marks of turning tools into false magnetic marks according to claim 1, wherein the AR module is correspondingly connected with a display unit to display the mixed image.

3. The system for screening the magnetic marks of the turning tool marks into the false magnetic marks according to claim 2, characterized by further comprising a checking module, wherein after the mixed image displayed by the display unit is manually screened, the mark of the image marking module is corrected according to a manual screening result.

4. The system for screening magnetic marks of turning tools according to claim 1, wherein the image acquisition device is a CCD camera.

5. The system for screening magnetic marks of turning tool marks into false magnetic marks according to claim 1, wherein the evaluation module has a function of identifying a standard magnetic powder inspection test piece so as to identify the definition of the standard magnetic powder inspection test piece.

6. A method for screening lathe tool marks from false magnetic marks is characterized by comprising the following steps:

step S1, putting a workpiece to be screened into the magnetic powder inspection equipment, and determining a field range capable of displaying the accumulation morphology of the magnetic marks;

step S2, utilizing image acquisition equipment to directly face the field range of the magnetic powder inspection equipment, and carrying out real image acquisition on the accumulation morphology of the magnetic traces;

step S3, storing a plurality of screening images with magnetic trace accumulation morphology in a database, and marking the magnetic trace evaluation of the screening images;

step S4, mixing the virtual image and the screening image one by one through an AR module to form a mixed image;

step S5, comparing the coincidence degree of the virtual image and the discriminated image in the mixed image through an evaluation module, discriminating the magnetic traces in the real image according to the comparison result and outputting the evaluation result;

and step S6, marking the evaluation result of the real image screened by the evaluation module through an image marking module, and storing the marked real image into the database.

7. The method for screening the magnetic marks of the turning tool marks into the false magnetic marks according to claim 6, wherein the AR module is correspondingly connected with a display unit so as to display the mixed image.

8. The method for screening the magnetic traces of the turning tool marks into the false magnetic traces according to claim 7, wherein the method further comprises a step S7 of correcting the mark of the image marking module according to the manual screening result after the mixed image displayed by the display unit is manually screened by the verification module.

9. The method for screening magnetic marks of turning tools according to claim 6, wherein the image acquisition equipment is a CCD camera.

10. The method for screening the magnetic marks of the turning tool marks into the false magnetic marks according to claim 6, wherein the evaluation module has a magnetic powder inspection standard test piece identification function so as to identify the definition of the magnetic powder inspection standard test piece.

Background

The fluorescent magnetic powder alternating current magnetization inspection method is used for inspecting cracks, folds, wrinkles, inclusions and other discontinuity defects on the surface or near the surface of a ferromagnetic material. When the surface of the workpiece has defects, the magnetic permeability mu of air at the defects is very small, the magnetic resistance is very large, and magnetic lines of force are difficult to pass through the defects. At the moment, the magnetic circuit is changed, so that a part of magnetic lines of force are extruded to the lower part of the tip of the defect to pass through, a part of magnetic lines of force are extruded to the surface of the workpiece and then enter the workpiece, and a small part of magnetic lines of force directly pass through the defect. The magnetic lines of force thus leaked from the surface of the workpiece form S, N poles, i.e., a leakage magnetic field.

The magnetic particle inspection is required to identify relevant magnetic marks, irrelevant magnetic marks and false magnetic marks for all magnetic mark displays. And the related magnetic marks need to be compared with an acceptance/rejection standard to determine whether the workpiece is qualified or not, and the non-related magnetic marks and the false magnetic marks are used as qualified product judgment. Irrelevant magnetic traces appear to be able to appear alone or to be patterned by certain conditions that do not require evaluation, such as changes in cross-section (e.g., keyways and drilled holes), inherent material properties (e.g., bi-metal weld interface), magnetic writing, etc., and oil, slag, etc. on the surface of the workpiece can also cause magnetic powder to agglomerate and form magnetic traces that can be eliminated after the surface of the workpiece is degreased and slag removed. And (3) false magnetic trace display, namely the false magnetic trace display is not caused by magnetic adsorption of magnetic powder and is magnetic trace display formed by a non-leakage magnetic field. For example, mechanically trapped magnetic particles, magnetic particles that fall or embed into the weld recess surface. The lathe tool mark is formed in the surface processing process and does not harm the quality of products. After the magnetic marks of the turning tool marks are cleaned, the turning tool marks are magnetized again and subjected to flaw detection again, the magnetic marks of the turning tool marks still reappear, and the key for accurately screening the turning tool marks into false magnetic marks is the fluorescent magnetic powder flaw detection. The existing method judges according to the experience and visual inspection of magnetic powder inspectors, and is difficult to accurately and quickly identify the turning tool mark area type magnetic marks according to false magnetic marks.

Therefore, there is a need to provide an improved solution to the above-mentioned deficiencies of the prior art.

Disclosure of Invention

The invention aims to overcome the defects in the prior art and provide a technology capable of rapidly monitoring magnetic marks of a workpiece to be screened.

In order to achieve the above purpose, the invention provides the following technical scheme:

a system for screening lathe tool marks from false magnetic marks, the system comprising:

the magnetic particle inspection equipment is used for carrying out surface magnetic particle inspection on a workpiece to be screened and has a view field range for displaying the accumulation morphology of magnetic marks;

the image acquisition equipment is over against the field range of the magnetic powder inspection equipment and is used for acquiring real images of the accumulation morphology of the magnetic marks;

the image processing module is used for extracting magnetic trace characteristics of the real image acquired by the image acquisition equipment to obtain a virtual image;

the magnetic mark evaluation method comprises the following steps that a database is stored, a plurality of discrimination images with magnetic mark accumulation appearances are stored in the database, and magnetic mark evaluation of the discrimination images is marked;

the AR module is used for mixing the virtual images and the discrimination images one by one to form mixed images;

the evaluation module is used for comparing the coincidence degree of the virtual image and the discriminated image in the mixed image, discriminating the magnetic traces in the real image according to the comparison result and outputting an evaluation result;

and the image marking module marks the evaluation result of the real image screened by the evaluation module and stores the marked real image into the database.

In the system for screening the turning tool marks into the false magnetic marks, preferably, the AR module is correspondingly connected with a display unit to display the mixed image.

The system for screening the turning tool marks into the false magnetic marks preferably further comprises a checking module, and after the mixed image displayed by the display unit is manually screened, the mark of the image marking module is corrected according to the manual screening result.

According to the system for screening the turning tool marks into the false magnetic marks, preferably, the image acquisition device is a CCD camera.

In the system for screening the turning tool mark magnetic mark into the false magnetic mark, preferably, the evaluation module has a function of identifying a magnetic powder inspection standard test piece so as to identify the definition of the magnetic powder inspection standard test piece.

A method for screening lathe tool marks from false magnetic marks, which comprises the following steps:

step S1, putting a workpiece to be screened into the magnetic powder inspection equipment, and determining a field range capable of displaying the accumulation morphology of the magnetic marks;

step S2, utilizing image acquisition equipment to directly face the field range of the magnetic powder inspection equipment, and carrying out real image acquisition on the accumulation morphology of the magnetic traces;

step S3, storing a plurality of screening images with magnetic trace accumulation morphology in a database, and marking the magnetic trace evaluation of the screening images;

step S4, mixing the virtual image and the screening image one by one through an AR module to form a mixed image;

step S5, comparing the coincidence degree of the virtual image and the discriminated image in the mixed image through an evaluation module, discriminating the magnetic traces in the real image according to the comparison result and outputting the evaluation result;

and step S6, marking the evaluation result of the real image screened by the evaluation module through an image marking module, and storing the marked real image into the database.

According to the method for screening the turning tool marks from the false magnetic marks, preferably, the AR module is correspondingly connected with a display unit to display the mixed image.

Preferably, the method further includes step S7, after the mixed image displayed by the display unit is manually screened by the verification module, the mark of the image marking module is corrected according to the manual screening result.

According to the method for screening the turning tool mark magnetic marks into the false magnetic marks, preferably, the image acquisition device is a CCD camera.

Preferably, the evaluation module has a function of identifying a standard test piece for magnetic powder inspection so as to identify the definition of the standard test piece for magnetic powder inspection.

Has the advantages that: analyzing the accumulation morphology of the magnetic traces in the field of view by using an AR technology, comparing the defect magnetic traces by using a virtual mixed image generated by mixing a real high-definition image of the magnetic traces shot by an image acquisition device with a screened image with an evaluation mark, and automatically outputting a magnetic trace evaluation result; in addition, an image marking module is arranged, and the database discrimination images are continuously learned and added, so that the system continuously accumulates and learns, and the discrimination capability of the defect magnetic marks is improved.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. Wherein:

FIG. 1 is a schematic structural diagram of a false magnetic mark screening system according to an embodiment of the present invention;

FIG. 2 is a graph showing the crack and tool marks of a round bar according to an embodiment of the present invention;

FIG. 3 is a graph showing the magnetic marks of square steel lathes in the embodiment of the present invention.

In the figure: 1. an image acquisition device; 2. an image processing module; an AR module; 4. a display; 5. an evaluation module; 6. an image marking module; 7. a database.

Detailed Description

The technical solutions in the embodiments of the present invention will be described clearly and completely below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.

The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings. It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.

As shown in fig. 1-3, a system for discriminating a turning tool mark from a false magnetic mark comprises:

the magnetic particle inspection device is used for performing surface magnetic particle inspection on a workpiece to be inspected, and is provided with a view field range for displaying the magnetic mark accumulation appearance, wherein the view field range is a rectangular area of 105mm and 148mm, the magnetic mark accumulation appearance of the workpiece to be inspected is displayed in the rectangle, and specifically, the selection standard of the view field range is referred to GB/T9444-2007; the image acquisition equipment 1 is over against the field range of the magnetic powder inspection equipment and is used for acquiring real images of the accumulation morphology of the magnetic marks; the image processing module 2 is used for extracting magnetic trace characteristics of the real image acquired by the image acquisition equipment 1 to obtain a virtual image; the database 7 is used for storing a plurality of discrimination images with magnetic trace accumulation morphology in the database 7 and marking the magnetic trace evaluation of the discrimination images; the AR module 3 is used for mixing the virtual images and the discrimination images one by one to form mixed images; the evaluation module 5 is used for comparing the coincidence degree of the virtual image and the discriminated image in the mixed image, discriminating the magnetic traces in the real image according to the comparison result and outputting an evaluation result; and the image marking module 6 marks the evaluation result of the real image screened by the evaluation module 5 and stores the marked real image into the database 7.

Analyzing the accumulation morphology of the magnetic traces in a visual field range by an Augmented Reality (AR) technology, comparing the defect magnetic traces by using a virtual mixed image generated by mixing a real high-definition image of the magnetic traces shot by the image acquisition equipment 1 and a screening image with an evaluation mark, and outputting the evaluation result of the magnetic traces automatically; in addition, the image marking module 6 is arranged, the database 7 is added for image discrimination in continuous learning, so that the system can continuously accumulate and learn, and the discrimination capability of the defect magnetic marks is improved.

In another optional embodiment of the present application, the AR module 3 is correspondingly connected with a display unit to display the mixed image. Specifically, the display unit is a display 4, the AR module 3 outputs the mixed image to the screen display 4, so that a user can observe the mixed image from the screen conveniently and perform manual discrimination and confirmation to combine and interact the defect magnetic marks recognized by human eyes as the recognition result of the system,

in another optional embodiment of the present application, the system further includes a verification module, and after the mixed image displayed by the display unit is subjected to manual magnetic trace screening, the mark of the image marking module 6 is corrected according to a manual screening result. Based on the result of human eye identification, the evaluation result of the system is finally verified, the system continuously learns the discrimination capability, discriminates image data after accumulation for a period of time and stores in a large amount, and the discrimination standard of the system is corrected, so that the system can accurately identify the defect magnetic marks, and the 'people oriented' is really realized.

In another alternative embodiment of the present application, the image acquisition device 1 is a CCD camera.

In another optional embodiment of the present application, the evaluation module 5 has a function of identifying a magnetic powder inspection standard test piece, so as to identify the sharpness of the magnetic powder inspection standard test piece. Whether a workpiece to be screened in a view field range is magnetized or not is judged through a magnetic powder inspection standard test piece, specifically, the type of the magnetic powder inspection standard test piece is A1-30/100 cross test piece, if the test piece is not clear, the workpiece to be screened is proved to be not magnetized or the magnetization degree is not enough, and at the moment, the defect magnetic trace evaluation of the workpiece is not carried out.

In another alternative embodiment of the present application, a method for discriminating a turning tool mark from a false magnetic mark is provided, where the method includes:

step S1, putting a workpiece to be screened into the magnetic powder inspection equipment, and determining a field range capable of displaying the accumulation morphology of the magnetic marks;

step S2, utilizing the image acquisition equipment 1 to just face the field range of the magnetic powder inspection equipment, and carrying out real image acquisition on the accumulation morphology of the magnetic traces;

step S3, storing a plurality of screening images with magnetic trace accumulation morphology in a database 7, and marking the magnetic trace evaluation of the screening images;

step S4, mixing the virtual image and the screening image one by the AR module 3 to form a mixed image;

step S5, the coincidence degree of the virtual image and the discriminated image in the mixed image is compared through the evaluation module 5, the magnetic traces in the real image are discriminated according to the comparison result, and the evaluation result is output;

in step S6, the image labeling module 6 labels the evaluation result of the real image screened by the evaluation module 5, and stores the labeled real image in the database 7.

Specifically, in step 1, a workpiece to be screened needs to be processed, and the processing technology includes: pretreatment: the preprocessing range must be larger than the field of view range; the detected surface of the workpiece to be screened is clean and dry and has no grease, rust, silt, oxide skin, welding flux and welding spatter; if the coating exists, the coating which influences the flaw detection sensitivity must be removed and cleaned, all the work of magnetic powder flaw detection must be cleaned, and flaw detection can be carried out after the appearance inspection is qualified. Magnetization: the magnetizing time, the required magnetic field direction and the required magnetic field intensity are determined according to the magnetism, the shape, the size, the surface condition, the defect property and the like of the test piece during the magnetization, and the magnetic powder inspection standard test piece is required to be used for inspection after the magnetization. Applying magnetic powder or magnetic suspension: applying magnetic powder or magnetic suspension by continuous method, stopping applying magnetic suspension or magnetic powder for 1 second, and stopping magnetization (power off). And after the treatment process is finished, the magnetic marks can be screened, the workpiece to be screened is demagnetized, and the workpiece to be screened is marked and recorded according to the evaluation result after the demagnetization is finished.

In another optional embodiment of the present application, the AR module 3 is correspondingly connected with a display unit to display the mixed image. In this embodiment, the method further includes step S7, after the verification module performs manual magnetic trace screening on the mixed image displayed by the display unit, the label of the image labeling module 6 is corrected according to the manual screening result. Based on the result of human eye identification, the evaluation result of the system is finally verified, the system continuously learns the discrimination capability, discriminates image data after accumulation for a period of time and stores in a large amount, and the discrimination standard of the system is corrected, so that the system can accurately identify the defect magnetic marks, and the 'people oriented' is really realized.

The method for screening the artificial magnetic marks comprises the following steps: 1. visually observing again to confirm that the turning tool mark is formed. 2. And (5) observing after bleaching and washing the magnetic marks of the car cutter marks again, wherein the magnetic marks are not generated. 3. And (5) performing penetrant flaw detection to verify magnetic marks without defects. The judging method is characterized in that factors of the magnetic marks of the turning tool marks are controlled and determined one by one, human factors are reduced, screening conditions are standardized, quality control of magnetic powder detection is improved, quality supervision and inspection are improved, consistency of magnetic mark judgment execution of fluorescent magnetic powder inspection after turning is guaranteed, and standardization of magnetic powder detection work is guaranteed. It should be noted that the method only discriminates the turning tool mark, and does not discriminate the crack, the scribe line, and the like.

In another alternative embodiment of the present application, the image acquisition device 1 is a CCD camera.

In another optional embodiment of the present application, the evaluation module 5 has a function of identifying a magnetic powder inspection standard test piece, so as to identify the sharpness of the magnetic powder inspection standard test piece.

Specifically, the database 7 also has discrimination condition data for discriminating whether the specimen definition, the magnetic mark definition, and the like meet the discrimination requirements; the discrimination condition data are test piece images or magnetic trace images with different definitions, the evaluation module 5 compares the test piece or magnetic trace image collected by the image collecting device 1 with the discrimination condition data in the database 7, when the definition meets the discrimination requirement, the evaluation module 5 continues to discriminate the false magnetic trace, otherwise, the false magnetic trace discrimination is not performed and prompt information is output.

The invention can not only eliminate different factors of different judgment results of experience difference between people, but also analyze, compare and classify the appearance and the size of the magnetic marks of the lathe tool marks, thereby having higher detection efficiency.

In another optional embodiment of the application, 2 long round steel bars (specification phi 120mm) +1 square steel (240mm multiplied by 240mm) are selected as workpieces to be screened, the length is 6 meters, the surfaces of the workpieces are machined, turning tool marks exist, the 1# workpiece long round steel bars have long surface cracks, the 2# long round steel bar workpieces do not have surface cracks, and the 3# square steel workpieces do not have surface cracks. The criteria for discriminating, analyzing and judging the magnetic traces are shown in the following table:

according to the magnetic powder inspection standard regulation: judging the false magnetic marks and the non-related magnetic marks as qualified products of magnetic powder inspection, and judging the related magnetic marks as unqualified products of magnetic powder inspection; when the discrimination is carried out, the coincidence degree of the real image after the characteristic extraction and the discriminated image in the database reaches more than 80 percent, and then the mark of the discriminated image can be output as an output result.

In conclusion, the invention provides a system and a method for discriminating a turning tool mark magnetic mark into a false magnetic mark, the discrimination is carried out according to the AR technology, a real magnetic mark high-definition image shot by an image acquisition device 1 and a virtual mixed image generated by mixing a discriminated image with an evaluation mark are utilized, the defect magnetic mark is compared through the mixed image, a magnetic mark evaluation result is automatically output, different factors of evaluation results with different experience between people can be eliminated, the appearance and the size of the magnetic mark of the turning tool mark can be analyzed, compared and classified, and the detection efficiency is higher.

The invention is not to be considered as limited to the particular embodiments shown, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

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