CN113960091A - Automatic detection system and automatic detection method for nonferrous metals - Google Patents
Automatic detection system and automatic detection method for nonferrous metals Download PDFInfo
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Abstract
The invention discloses an automatic detection system and an automatic detection method for nonferrous metals, relates to the technical field of nonferrous metal detection, and aims to solve the problems that the manual detection efficiency is limited, the labor intensity is high, and the production requirement of the metallurgical industry cannot be met; the automatic sample milling machine comprises a control module, a pneumatic sample feeding system, a mechanical arm, a sample and sample bottle separating device, a full-automatic sample milling machine, a sample conversion table, a vision system, an X-ray fluorescence spectrometer and an automatic sealing filing device, wherein the pneumatic sample feeding system, the mechanical arm, the sample and sample bottle separating device, the full-automatic sample milling machine, the sample conversion table, the vision system, the X-ray fluorescence spectrometer and the automatic sealing filing device are respectively in signal connection with the control module; the pneumatic sample conveying system conveys the bottled sample from the sampling point to the pneumatic conveying receiving and sending cabinet through a pneumatic conveying pipeline, and conveys the empty sample bottle back to the sampling point; the sample conversion table comprises a fluorescence measurement sample cup placing position and a sample loading mechanism; the automatic sealing filing device comprises a labeling device, a sample sucking disc and a material box; the invention has reasonable design, can save the inspection time and cost, can meet the production requirements of the metallurgical industry and simultaneously reduces the labor intensity of inspectors.
Description
Technical Field
The invention relates to the technical field of non-ferrous metal detection, in particular to a non-ferrous metal automatic detection system and an automatic detection method.
Background
At present, the analysis of nonferrous metal samples adopts inductively coupled plasma emission spectrometry (ICP), the detection period of the method is long, and a large amount of acid and alkali chemical reagents are used. With the increasing requirements of the metallurgical industry on the quality of hot galvanizing industrial products, the inspection frequency is high, the period requirement is short, and the ICP analysis method is difficult to meet the requirements of intelligent and green development of the metallurgical industry.
In contrast, a scholars proposes the possibility of analyzing the zinc coating by using an X-ray fluorescence analysis method, for example, in the article "research on weight measurement model and control method of zinc coating on strip steel in continuous hot galvanizing production line" of the university of Wuhan science and technology, the good linear relationship between the fluorescence intensity of zinc and the weight of the zinc coating is recorded; however, the production requirements of the metallurgical industry cannot be well met only by replacing the inspection method, and meanwhile, the working strength of the inspection personnel is high due to mass production and frequent sampling inspection, the detection consistency of the personnel is difficult to keep unchanged, and the result is slightly influenced, so that an automatic detection system and an automatic detection method for nonferrous metals are urgently needed to solve the problem.
Disclosure of Invention
The invention aims to provide an automatic detection system and an automatic detection method for nonferrous metals, and aims to solve the problems that manual detection efficiency is limited, labor intensity is high, and production requirements of the metallurgical industry cannot be met.
In order to achieve the purpose, the invention provides the following technical scheme: an automatic detection system for nonferrous metals comprises a control module, a pneumatic sample feeding system, a manipulator, a sample and sample bottle separating device, a full-automatic sample milling machine, a sample conversion table, a vision system, an X-ray fluorescence spectrometer and an automatic sealing and filing device, wherein the pneumatic sample feeding system, the manipulator, the sample and sample bottle separating device, the full-automatic sample milling machine, the sample conversion table, the vision system, the X-ray fluorescence spectrometer and the automatic sealing and filing device are respectively in signal connection with the control module;
the pneumatic sample conveying system conveys the bottled sample from the sampling point to the pneumatic conveying receiving and sending cabinet through a pneumatic conveying pipeline, and conveys the empty sample bottle back to the sampling point;
the sample conversion table comprises a fluorescence measurement sample cup placing position and a sample loading mechanism;
the automatic sealing filing device comprises a labeling device, a sample sucking disc and a material box;
the full-automatic sample milling machine is provided with a first sample conveying device, the X-ray fluorescence spectrometer is provided with a second sample conveying device, the automatic sealing filing device is provided with a third sample conveying device, and the moving range of the manipulator comprises a pneumatic conveying receiving and sending cabinet, a sample and sample bottle separating device, a sample conversion table, a visual system, the first sample conveying device, the second sample conveying device and the third sample conveying device.
In a preferred scheme, a desktop is arranged at the control module, and the sample and sample bottle separating device, the sample conversion table and the vision system are all arranged on the desktop.
In a preferred embodiment, the sample and sample bottle separating device is provided with a pneumatic sampling suction cup for sucking the sample out of the sample bottle.
In a preferred scheme, the vision system comprises an image acquisition module and an image processing module, and is used for judging the surface quality of a sample processed by the full-automatic sample milling machine.
In a preferred embodiment, the sample conversion station comprises a cylindrical boss having a diameter smaller than the bottom detection hole of the fluorometric sample cup.
The invention provides another technical scheme that: an automatic detection method for nonferrous metals, which adopts the automatic detection system in any scheme, comprises the following steps:
s1, sampling and loading the sample into a sample bottle, and conveying the sample bottle with the sample to a pneumatic conveying receiving and dispatching cabinet by utilizing compressed air through a pneumatic conveying pipeline;
s2, the manipulator clamps and moves a sample bottle with a sample to a sample and sample bottle separating device, after the pneumatic sampling sucker sucks out the sample, the manipulator sends the empty sample bottle back to the air sending and receiving cabinet, the sample bottle is sent back to a sampling point through a pneumatic conveying pipeline by utilizing reverse compressed air, and the manipulator clamps the sample from the pneumatic sampling sucker and moves the sample to a first sample conveying device;
s3, the first sample conveying device conveys the sample into a full-automatic sample milling machine, a cylinder clamping jaw in the full-automatic sample milling machine clamps the sample, surface milling sample preparation is carried out, and the sample is conveyed out through the first sample conveying device after treatment;
s4, clamping the fluorescence measurement sample cup by the manipulator and placing the fluorescence measurement sample cup on a sample conversion table, clamping the sample from the first sample conveying device to the sample conversion table, and placing the fluorescence measurement sample cup into the sample conversion table with the detection surface of the sample facing downwards;
s5, clamping by a manipulator; the fluorescence measurement sample cup with the sample is sent to a vision system, a detection surface image is collected, the surface quality of the detection surface image is judged, and if the detection surface image is qualified, the sample is sent to a second sample conveying device by a manipulator;
s6, the second sample conveying device conveys the sample to the X-ray fluorescence spectrometer and samples the sample to the sample introduction system, the X-ray fluorescence spectrometer detects the sample and stores the result, and the second sample conveying device conveys the sample out after the detection;
s7, the manipulator places the fluorescence measurement sample cup filled with the detected sample on the sample conversion table from the second sample conveying device, clamps the detected sample and conveys the sample to the third sample conveying device, and the third sample conveying device conveys the sample to the automatic sealing filing device for labeling and storing.
In a preferred embodiment, if the sample is not qualified in step S5, the manipulator sends the sample to the full-automatic sample milling machine for re-milling, and the full-automatic sample milling machine is determined again by the vision system, and if the sample is not qualified, the manipulator directly sends the sample to the third sample conveying device, and the third sample conveying device sends the sample to the automatic sealing filing device for labeling and storing.
In a preferred scheme, the sample conversion table comprises a cylindrical boss, the diameter of the cylindrical boss is smaller than that of a detection hole at the bottom of the fluorescence measurement sample cup, in the step S4, the manipulator clamps the fluorescence measurement sample cup, makes the detection hole pass through the boss and place the fluorescence measurement sample cup on a table top, clamps the sample again and places the sample on the boss, and finally clamps the fluorescence measurement sample cup and lifts the fluorescence measurement sample cup to finish the sample loading; in step S7, the manipulator grips the fluorescence measurement sample cup containing the detected sample to the upper side of the boss, and the boss is aligned with the detection hole at the bottom of the fluorescence measurement sample cup, during the descending process, the sample is left on the boss to be gripped, and the fluorescence measurement sample cup is placed on the table to be held for the next sample loading.
In an optional scheme, the control module comprises a PLC controller in signal connection and a computer with a control program, wherein the PLC controller is responsible for signal acquisition and control of each device, and the computer is responsible for manipulator flow coordination, device calling, parameter adjustment and instruction issuing.
Compared with the prior art, the invention has the beneficial effects that:
the automatic detection system and the automatic detection method for the nonferrous metal adopt full-automatic system design and X-ray fluorescence spectrum analysis, compared with the original manual ICP detection, the detection efficiency of the nonferrous metal sample can be greatly improved, so that the production and detection requirements of hot galvanizing industrial products are met, and the actual requirements are met; meanwhile, the method can also reduce the inspection cost of the non-ferrous metal sample, reduce the labor intensity of inspectors, reduce the use of acid and alkali chemical reagents, reduce the discharge of waste liquid, and meet the requirements of modern enterprises on energy conservation, emission reduction and low-carbon production.
Drawings
FIG. 1 is a schematic top view of the present invention;
FIG. 2 is a schematic view of an operating state of the sample conversion stage of the present invention;
FIG. 3 is a schematic diagram of an automatic detection process according to the present invention.
In the figure: 1. a pneumatic conveying pipeline; 2. an air-conveying receiving and sending cabinet; 3. a manipulator; 4. a sample and sample bottle separation device; 5. a first sample transport device; 6. a full-automatic sample milling machine; 7. a sample conversion stage; 8. a vision system; 9. a second sample transfer device; 10. an X-ray fluorescence spectrometer; 11. a control module; 12. a third sample transfer device; 13. automatic sealing filing device.
Detailed Description
As shown in fig. 1, an automatic detection system for nonferrous metals comprises a control module 11, and a pneumatic sample feeding system, a manipulator 3, a sample and sample bottle separation device 4, a full-automatic sample milling machine 6, a sample conversion table 7, a vision system 8, an X-ray fluorescence spectrometer 10 and an automatic sealing filing device 13 which are respectively in signal connection with the control module 11;
the pneumatic sample conveying system conveys the bottled sample from a sampling point to a pneumatic conveying receiving and sending cabinet 2 through a pneumatic conveying pipeline 1, and conveys the empty sample bottle back to the sampling point;
the sample conversion table 7 comprises a fluorescence measurement sample cup placing position and a sample loading mechanism;
the automatic sealing filing device 13 comprises a labeling device, a sample sucking disc and a material box;
the full-automatic sample milling machine 6 is provided with a first sample conveying device 5, the X-ray fluorescence spectrometer 10 is provided with a second sample conveying device 9, the automatic sealing filing device 13 is provided with a third sample conveying device 12, and the moving range of the manipulator 3 comprises a pneumatic conveying receiving and sending cabinet 2, a sample and sample bottle separating device 4, a sample conversion table 7, a visual system 8, the first sample conveying device 5, the second sample conveying device 9 and the third sample conveying device 12.
Preferably, the control module 11 is provided with a desktop, and the sample and sample bottle separating device 4, the sample conversion table 7 and the vision system 8 are all arranged on the desktop, so that an operator can fix the desktop for working, and can observe the image condition of the vision system 8 and the like while operating the control module 11.
The sample and specimen bottle separating apparatus 4 is preferably provided with a pneumatic sampling suction cup for sucking the sample out of the specimen bottle.
The vision system 8 comprises an image acquisition module and an image processing module and is used for judging the surface quality of the sample processed by the full-automatic sample milling machine 6.
As shown in fig. 2, the sample conversion stage 7 may adopt the following structure: the device comprises a cylindrical boss, the diameter of the cylindrical boss is smaller than a detection hole at the bottom of a fluorescence measurement sample cup, the diameter is generally 32mm, and the height of the boss can be set to be 42mm, which is slightly higher than the fluorescence measurement sample cup.
The detection method of the automatic detection system comprises the following steps:
s1, sampling and loading the sample into a sample bottle, and conveying the sample bottle with the sample to a pneumatic conveying receiving and dispatching cabinet 2 through a pneumatic conveying pipeline 1 by utilizing compressed air;
s2, the manipulator 3 clamps and moves a sample bottle with a sample to the sample and sample bottle separating device 4, after the pneumatic sampling sucker sucks the sample, the manipulator 3 sends the empty sample bottle back to the receiving and sending cabinet 2, the sample bottle is sent back to a sampling point through the pneumatic conveying pipeline 1 by utilizing reverse compressed air, and the manipulator 3 clamps the sample from the pneumatic sampling sucker and moves to the first sample conveying device 5;
s3, the first sample conveying device 5 conveys the sample into the full-automatic sample milling machine 6, a cylinder clamping jaw in the full-automatic sample milling machine clamps the sample, surface milling sample preparation is carried out, and the sample is conveyed out through the first sample conveying device 5 after treatment;
s4, the manipulator 3 clamps the fluorescence measurement sample cup and places the fluorescence measurement sample cup on the sample conversion table 7, then the first sample conveying device 5 clamps the sample on the sample conversion table 7, and the sample detection surface is placed in the fluorescence measurement sample cup in a downward mode;
s5, clamping by the manipulator 3; the fluorescence measurement sample cup with the sample is sent to a vision system 8, a detection surface image is collected, the surface quality of the detection surface image is judged, and if the detection surface image is qualified, the manipulator 3 sends the sample to a second sample conveying device 9;
s6, the second sample conveying device 9 conveys the sample to the X-ray fluorescence spectrometer 10, and samples to the sample introduction system, the X-ray fluorescence spectrometer 10 detects the sample and stores the result, specifically, the X-ray irradiation generates the secondary X-ray (X fluorescence), the crystal is used for light splitting, the detector is used for measuring the intensity of the secondary X-ray at the selected wavelength position, the content of each element in the sample is obtained according to the working curve drawn by the calibration sample, and the second sample conveying device 9 sends out the sample after the detection;
s7, the manipulator 3 places the fluorescence measurement sample cup containing the detected sample on the sample conversion table 7 from the second sample conveying device 9, clamps the detected sample and conveys the sample to the third sample conveying device 12, and the third sample conveying device 12 conveys the sample to the automatic sealing filing device 13 for labeling and preservation.
The following may be adopted for the processing that is not qualified in step S5: if the sample is not qualified, the manipulator 3 sends the sample to the full-automatic sample milling machine 6 for re-milling, and the judgment is carried out by the vision system 8 again, if the sample is not qualified, the manipulator 3 directly sends the sample to the third sample conveying device 12, and the third sample conveying device 12 sends the sample to the automatic sealing filing device 13 for labeling and storage.
When the sample conversion table 7 adopts the cylindrical boss structure shown in fig. 2, in step S4, the manipulator 3 grips the fluorescence measurement sample cup and places the detection hole thereof on the table top through the boss, the manipulator 3 grips the sample and places the sample on the boss, and finally the gripping fluorescence measurement sample cup is lifted up to complete the sample loading; in step S7, the manipulator 3 grips the fluorescence measurement sample cup containing the detected sample to the upper side of the boss, and the boss is aligned with the detection hole at the bottom of the fluorescence measurement sample cup, during the descending process, the sample is left on the boss to be gripped, and the fluorescence measurement sample cup is placed on the table to be held next time.
In a preferred embodiment, the control module 11 includes a PLC controller in signal connection with a computer having a control program installed therein, wherein the PLC controller is responsible for signal acquisition and control of each device, and the computer is responsible for manipulator flow coordination, device invocation, parameter adjustment, and instruction issue; of course, the control module 11 may also use only a PLC controller or a DCS control system to complete the steps of the method, but it is better to use the preferred embodiment for the sake of process coordination and fluency.
Example (b):
in the embodiment, the scheme in the above embodiment is adopted, so that ICP manual inspection of the company is comprehensively modified, in addition, the manipulator 3 in the scheme adopts a 6-axis robot of the shanghai ABB company, the PLC controller in the control module 11 adopts a siemens PLC control system, a control program in the computer is an IPS main control system of the shanghai ABB company, and the PLC control system is also connected to the IPS main control system and issues all instructions through the IPS main control system; in addition, the X-ray fluorescence spectrometer 10 also uploads the detection result to the IPS main control system of the computer for storage;
the following are all direct applications of the prior art: the pneumatic sample conveying system adopts a commercially available ZRS-AT single-tube combined positive-pressure reciprocating type pneumatic sample conveying device; the full-automatic sample milling machine 6 is a common commercially available model; the vision system 8 comprises a light source, a lens, a camera, an image acquisition card and image processing software, extracts target characteristics through operation, outputs results according to preset tolerance and other conditions, and is used for checking whether the surface of the milled nonferrous metal sample reaches the surface quality required by fluorescence analysis; the first sample conveying device 5, the second sample conveying device 9 and the third sample conveying device 12 are matched by a platform trolley which is accurately positioned by a servo motor and a micro clamping jaw, so that the accurate dispatching of samples is realized.
After the transformation is carried out, the detection time of a single sample is shortened to 6 minutes from the original 40 minutes, the production inspection requirements can be met, and the cost is saved and calculated as follows:
sample amount: 720/month (in 2020.05 to 2020.09 average work volume); reducing the use amount of 15 chemical reagents and standard solutions, wherein the use amount of the chemical reagents and the standard solutions is calculated according to 2 yuan for each reagent, and the reduced use amount multiplied by the reagent cost multiplied by the time is 15 multiplied by 720 multiplied by 2 multiplied by 12 months is 25.92 ten thousand yuan/year;
manpower is saved: the full-automatic inspection is used according to the calculation of the annual cost of 16 ten thousand yuan (about 75.8 yuan/hour), so that the labor cost can be saved: shortening cycle times sample quantity times hour wage times (40-6)/60 times 720 times 75.8 times 12 times 37.11 ten thousand yuan/year;
the cost is saved by about 63 ten thousand yuan each year, the use of acid and alkali chemical reagents is reduced, the discharge of waste liquid is reduced, the requirements of modern enterprises on energy conservation, emission reduction and low-carbon production are met, the labor intensity can be reduced, and the operation of a control module by culture and inspection personnel is only needed.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are also included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope defined by the claims.
The present invention is not described in detail, but is known to those skilled in the art.
Claims (9)
1. The utility model provides a non ferrous metal automatic check out system which characterized in that: the automatic sample milling machine comprises a control module (11), and a pneumatic sample feeding system, a manipulator (3), a sample and sample bottle separating device (4), a full-automatic sample milling machine (6), a sample conversion table (7), a vision system (8), an X-ray fluorescence spectrometer (10) and an automatic sealing filing device (13) which are respectively in signal connection with the control module (11);
the pneumatic sample conveying system conveys the bottled sample from a sampling point to a pneumatic receiving and sending cabinet (2) through a pneumatic conveying pipeline (1), and conveys the empty sample bottle back to the sampling point;
the sample conversion table (7) comprises a fluorescence measurement sample cup placing position and a sample loading mechanism;
the automatic sealing filing device (13) comprises a labeling device, a sample sucker and a material box;
the full-automatic sample milling machine (6) is provided with a first sample conveying device (5), the X-ray fluorescence spectrometer (10) is provided with a second sample conveying device (9), the automatic sealing and filing device (13) is provided with a third sample conveying device (12), and the moving range of the manipulator (3) comprises a pneumatic conveying receiving and sending cabinet (2), a sample and sample bottle separating device (4), a sample conversion table (7), a visual system (8), the first sample conveying device (5), the second sample conveying device (9) and the third sample conveying device (12).
2. The automatic non-ferrous metal detection system according to claim 1, characterized in that: a desktop is arranged at the position of the control module (11), and the sample and sample bottle separating device (4), the sample conversion table (7) and the vision system (8) are all arranged on the desktop.
3. The automatic non-ferrous metal detection system according to claim 1, characterized in that: the sample and sample bottle separation device (4) is provided with a pneumatic sampling sucker and is used for sucking the sample out of the sample bottle.
4. The automatic non-ferrous metal detection system according to claim 1, characterized in that: the vision system (8) comprises an image acquisition module and an image processing module and is used for judging the surface quality of the sample processed by the full-automatic sample milling machine (6).
5. The automatic non-ferrous metal detection system according to claim 1, characterized in that: the sample conversion table (7) comprises a cylindrical boss, and the diameter of the cylindrical boss is smaller than the detection hole at the bottom of the fluorescence measurement sample cup.
6. An automatic detection method of nonferrous metals, which adopts the automatic detection system of any one of claims 1 to 5, and is characterized by comprising the following specific steps:
s1, sampling and loading the sample into a sample bottle, and conveying the sample bottle with the sample to a pneumatic conveying receiving and dispatching cabinet (2) by utilizing compressed air through a pneumatic conveying pipeline (1);
s2, the manipulator (3) clamps the sample bottle with the sample and moves the sample bottle to the sample and sample bottle separating device (4), after the sample is sucked out by the pneumatic sampling sucker, the manipulator (3) sends the empty sample bottle back to the air sending and receiving cabinet (2), the sample bottle is sent back to the sampling point by the reverse compressed air through the pneumatic conveying pipeline (1), and the manipulator (3) clamps the sample from the pneumatic sampling sucker and moves the sample bottle to the first sample conveying device (5);
s3, the first sample conveying device (5) conveys the sample into a full-automatic sample milling machine (6), a cylinder clamping jaw in the sample milling machine clamps the sample, surface milling sample preparation is carried out, and the sample is conveyed out through the first sample conveying device (5) after treatment;
s4, the manipulator (3) clamps the fluorescence measurement sample cup and places the fluorescence measurement sample cup on the sample conversion table (7), then the first sample conveying device (5) clamps the sample on the sample conversion table (7), and the sample is placed into the fluorescence measurement sample cup with the detection surface facing downwards;
s5, clamping by a manipulator (3); the fluorescence measurement sample cup with the sample is sent to a vision system (8), a detection surface image is collected, the surface quality of the detection surface image is judged, and if the detection surface image is qualified, the manipulator (3) sends the sample to a second sample conveying device (9);
s6, the second sample conveying device (9) conveys the sample to the X-ray fluorescence spectrometer (10) and samples the sample to the sample introduction system, the X-ray fluorescence spectrometer (10) detects the sample and stores the result, and the second sample conveying device (9) conveys the sample out after the detection;
s7, the manipulator (3) places the fluorescence measurement sample cup filled with the detected sample on the sample conversion table (7) from the second sample conveying device (9), clamps the detected sample and conveys the sample to the third sample conveying device (12), and the third sample conveying device (12) conveys the sample to the automatic sealing filing device (13) for labeling and storing.
7. The automatic detection method of nonferrous metal according to claim 6, characterized in that: in the step S5, if the sample is not qualified, the manipulator (3) sends the sample to the full-automatic sample milling machine (6) for re-milling, and the full-automatic sample milling machine is judged by the vision system (8) again, and if the sample is not qualified, the manipulator (3) directly sends the sample to the third sample conveying device (12), and the third sample conveying device (12) sends the sample to the automatic sealing filing device (13) for labeling and storing.
8. The automatic detection method of nonferrous metal according to claim 6, characterized in that: the sample conversion table (7) comprises a cylindrical boss, the diameter of the cylindrical boss is smaller than that of a detection hole at the bottom of the fluorescence measurement sample cup, in step S4, the manipulator (3) clamps the fluorescence measurement sample cup, the detection hole of the fluorescence measurement sample cup penetrates through the boss and is placed on a table top, the manipulator (3) clamps the sample and places the sample on the boss, and finally the fluorescence measurement sample cup is clamped and lifted to finish sample loading; in the step S7, the manipulator (3) clamps the fluorescence measurement sample cup filled with the detected sample to the upper part of the boss, the boss is aligned with the detection hole at the bottom of the fluorescence measurement sample cup, the sample is left on the boss to be clamped in the descending process, and the fluorescence measurement sample cup is placed on the table top to be loaded next time.
9. The automatic detection method of nonferrous metal according to claim 6, characterized in that: the control module (11) comprises a PLC controller in signal connection and a computer provided with a control program, wherein the PLC controller is responsible for signal acquisition and control of each device, and the computer is responsible for manipulator flow coordination, device calling, parameter adjustment and instruction issuing.
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