锻件自动化检测分选工位，尺寸、外观不良自动分拣｜Automated Inspection and Sorting Station for Forgings

摘要：锻件成型后，通过机器视觉、位移传感器完成外观、尺寸检测，自动把合格件、不良件分开。讲解产线集成方案。
Abstract: After forming, machine vision and displacement sensors check appearance and dimensions, then sort good parts from rejects automatically. This article explains the line integration.

正文： 锻件完成热切边冷却之后，传统依靠人工肉眼、卡尺分选，人疲劳之后漏检率高。自动化检测分选，就是在线完成检测，自动分拣合格品、不同类型不良品。
Main text: After trimming and cooling, manual sorting with eyes and calipers misses defects when people tire. An automated station inspects on line and sorts good parts from different reject types automatically.

硬件组成
Hardware

输送料道、定位工装、视觉相机 / 激光测头、剔除气缸、料箱（合格箱、不良品分箱）、电控系统。
Conveyor, locating fixture, vision cameras or laser sensors, reject cylinders, bins for good and sorted-bad parts, and the control system.

检测内容与流程
What is checked and how

锻件外形缺料、裂纹、毛刺过大、关键尺寸超差。流程：锻件随输送线到达检测工位，定位，视觉 / 传感器采集，系统判定，合格流往下工序；不良件根据缺陷类型，分别剔除进入对应料箱。
Checks cover missing material, cracks, excessive flash and out-of-tolerance dimensions. Parts arrive, locate, get scanned, and the system judges: good parts continue; rejects are ejected into type-specific bins.

实施要点
Implementation notes

• 表面干扰：锻件表面高温、氧化皮、油污会干扰视觉，必要时增加风冷、吹扫清理。
  Surface interference: heat, scale and oil confuse vision systems – add air cooling and purge where needed.
• 多品种切换：多品种生产需要做程序快速切换。
  Changeover: mixed production needs fast program switching.
• 数据留存：检测数据保存，绑定生产批次，统计不良类型占比，反向给工艺做优化参考。
  Data: save results against the batch, tally defect types, and feed the statistics back to process improvement.

半自动化方案
Semi-automatic option

中小企业可以采用半自动化：人工摆放锻件，设备自动检测分选，降低投入。
Smaller shops can place parts by hand and let the machine inspect and sort – much lower investment.