Integrated scratch five-axis automatic test system

Abstract

The application discloses an integrated scratch five-axis automatic testing system, which comprises a device platform, a tape testing mechanism, an upper die assembly mechanism and a lower die assembly mechanism. The tape testing mechanism is used for sticking and testing the products after the scratch grid. The upper die assembly mechanism is used for providing X and Z direction movement for the scratch cutter and performing photographing detection on the products. The lower die assembly mechanism is used for providing Y direction movement for the jig platform and performing horizontal rotation and predetermined angle overturning on the jig platform. The testing system further comprises a PLC control system. According to the integrated idea, the application guarantees the testing consistency to the maximum extent. The jig platform realizes accurate positioning by fixing the sample through paraffin heating and cooling. The stepping motor pressurizes, the software system controls the pressure, the rotating platform mechanism ensures multi-directional scratch (5° step), the CCD automatically identifies the area of the stripping area after the adhesive stripping, and the results are automatically judged. Through the double-axis rotating platform setting, the application is not only suitable for planar products, but also suitable for arc surface products.

Description

Technical Field

[0001] This invention belongs to the field of coating and plating performance testing technology, specifically relating to an integrated five-axis automatic scratch testing system. Background Technology

[0002] For corrosion resistance and aesthetic purposes, metal materials or magnetic products require electroplating or spraying coatings on the metal substrate. However, in actual use, these coatings may peel off, necessitating testing of the adhesion of the plating or coating. The conventional method for verifying products before failure is cross-cut testing. Currently, cross-cut testing relies on manual methods, which is limited by the wide variety of product sizes and types. However, the force, stroke, and grid size applied by different people vary, leading to errors in the results. Furthermore, after cross-cutting, adhesives need to be applied and the coating removed. Currently, product evaluation also relies on manual comparison, resulting in low efficiency and accuracy.

[0003] In addition, the existing cross-cut testers or 100-grid cross-cut testers available on the market are mainly used for scratch and abrasion resistance testing of painted or plastic surfaces. They work by fixing a large product (greater than 10cm*10cm), the mechanism contacts the product, and after applying pressure to a specified force value, the mechanism begins to slide. After the unidirectional marking is completed, the sample needs to be disassembled, rotated 90 degrees, and then fixed again before applying pressure and marking. After the marking is completed, subsequent testing steps and judgments still need to be performed manually, which results in relatively low efficiency and accuracy. Regarding product size applicability, existing equipment cannot quickly position and clamp small samples (less than 1cm*1cm). Regarding coating applicability, for composite metal layers with multiple layers, the toughness is better than paint layers. However, due to the more complex requirements for scratch depth, the selection of indenter and force values ​​for such products is limited. In terms of efficiency, the product needs to be disassembled and then reassembled, resulting in relatively lower efficiency. Furthermore, after the cross-cut test, other steps such as adhesive application, peeling, and judgment are required. Existing testing equipment can only complete the grid marking and cannot perform subsequent actions, still relying heavily on manual labor, thus offering minimal help in improving efficiency and test consistency.

[0004] In addition, existing equipment can only perform scribing on flat products, and is ineffective on curved products. In view of the above problems, it is of great significance to develop an integrated five-axis automatic scratch testing system to improve the automation level, work efficiency and accuracy of testing, as well as expand the application scope. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides an integrated five-axis automatic scratch testing system, which solves the technical problems of poor test consistency, cumbersome procedures and low efficiency, large amount of manual intervention, and poor product universality in the prior art.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An integrated five-axis automatic scratch testing system includes an equipment platform and a tape testing mechanism, an upper module mechanism, and a lower module mechanism mounted on the equipment platform. The tape testing mechanism is used to perform adhesion testing on products after scratching. The upper module mechanism is used to move the scratching tool in the X and Z directions and to photograph and inspect the product. The lower module mechanism is used to move the product fixture platform in the Y direction and to rotate the product fixture platform horizontally and flip it at a predetermined angle. The automatic testing system also includes a PLC control system.

[0007] As a further technical solution of the present invention, the tape testing mechanism includes a support column, a lifting cylinder, a servo motor, a base plate, a baffle mechanism, and a tape. The support column is set on the equipment platform, the lifting cylinder is set on the support column, and the base plate is connected above the lifting cylinder. The baffle mechanism is set on the base plate, and the servo motor and the tape are respectively set on both sides of the baffle mechanism and connected by a coupling. The servo motor is used to realize the unfolding of the tape.

[0008] As a further technical solution of the present invention, the upper module mechanism includes a mechanism base, an X-axis module, a Z-axis module, a tool positioning mechanism, and a CCD detection mechanism. The mechanism base is positioned on the equipment platform. An X-axis module is provided on the mechanism base. A first slide rail and a cooperating first slider are provided on the X-axis module. The Z-axis module is fixedly mounted on the first slider. A second slide rail and a cooperating second slider are provided on the Z-axis module. The tool positioning mechanism is mounted on the second slider. The CCD detection mechanism is fixedly connected to the tool positioning mechanism.

[0009] As a further technical solution of the present invention, an auxiliary X-axis module is provided below the X-axis module. The auxiliary X-axis module is provided with a fourth slide rail and a cooperating fourth slider. The Z-axis module is fixedly connected to the fourth slider to achieve synchronous movement with the first slider.

[0010] As a further technical solution of the present invention, the tool positioning mechanism includes a main connecting plate, a first positioning block, a pressure sensor, and a second positioning block. The back of the main connecting plate is fixedly connected to the second slider, and a guide rail is provided on the front of the main connecting plate. The first positioning block and the second positioning block are disposed on the guide rail. The first positioning block is disposed at the top of the guide rail and is positioned with the top of the main connecting plate by a spring assembly. The second positioning block is disposed at the lower end of the guide rail. The pressure sensor is disposed between the first positioning block and the second positioning block and is connected to the first positioning block. A scratching tool is disposed on the second positioning block.

[0011] As a further technical solution of the present invention, the CCD detection mechanism includes a second main connecting plate and a CCD lens and a light source disposed on the second main connecting plate, wherein the light source is positioned below the CCD lens; the second main connecting plate is fixedly connected to the main connecting plate of the tool positioning mechanism.

[0012] As a further technical solution of the present invention, the lower module mechanism includes a Y-axis module, a motor fixing bracket, a first rotary motor, a second rotary motor, and a product fixture platform. The Y-axis module is fixed on the equipment platform, and a third slide rail and a cooperating third slider are provided on the Y-axis module. The motor fixing bracket is disposed on the third slider. The first rotary motor is disposed on the motor fixing bracket and connected to the product fixture platform through a first rotating component, which enables the product fixture platform to be flipped forward and backward at a predetermined angle. The second rotary motor is disposed below the product fixture platform and connected to the fixture platform through a second rotating component, which enables the product fixture platform to rotate at any angle within the plane.

[0013] As a further technical solution of the present invention, the tape testing mechanism is set at a predetermined distance in front of the product fixture platform along the Y-axis module direction, and the height of the tape is higher than the height of the product fixture platform.

[0014] As a further technical solution of the present invention, the PLC control system is electrically connected to the X-axis module, Y-axis module, Z-axis module, tape testing mechanism, CCD detection mechanism and pressure sensor respectively, for the purpose of realizing automated control of the entire system.

[0015] As a further technical solution of the present invention, the device platform is also equipped with a touch screen for operation and settings.

[0016] Compared with the prior art, the technical solution of the present invention has the following beneficial effects: (1) The product fixture platform is driven by a five-axis motor, which can achieve precise positioning in X, Y, and Z, as well as planar rotation and flipping at a predetermined angle, making it more widely applicable; (2) The integrated system of the present invention can realize a fully automated integrated process of grid division, adhesive peeling and automatic photo judgment; (3) The CCD detection mechanism of the present invention can automatically identify the area of ​​the peeled area after the adhesive is peeled off, and automatically determine it; (4) The present invention can realize the function of scribing arc surfaces. By rotating the fifth axis rotary table at a specified angle, it can scaffold the XY plane and space within an angle of 0-25°. (5) Multi-point (multi-product) testing can be achieved: multi-position programming testing can be performed through array fixtures; In summary, the technical solution of this invention, following an integrated approach, maximizes the consistency of testing. The fixture platform fixes the sample precisely by using paraffin heating and cooling in the slots to secure it. A stepper motor applies pressure, and the software system controls the pressure. The rotating platform mechanism ensures multi-directional scribing (5° steps). After adhesive peeling, the CCD automatically identifies the peeled area and automatically judges the results. Using the integrated mechanism of this invention, we achieve integrated inspection with constant force, fine mesh, automatic peeling, and automatic judgment, improving the automation level, efficiency, and accuracy of testing, and expanding its application range. The dual-axis rotating platform is suitable not only for flat products but also for curved products. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the integrated five-axis automatic scratch testing system of the present invention; Figure 2 for Figure 1 Top view; Figure 3 This is a schematic diagram of the tape testing mechanism of the present invention; Figure 4 This is a schematic diagram of the upper module mechanism of the present invention; Figure 5 This is a schematic diagram of the tool positioning mechanism of the present invention; Figure 6 This is a schematic diagram of the CCD detection mechanism of the present invention; Figure 7 This is a schematic diagram of the lower module mechanism of the present invention; Figure 8 for Figure 7 The front view; Figure 9 A standard diagram for determining the area of ​​the product stripping zone.

[0018] In the diagram: 1. Tape testing mechanism; 101. Support column; 102. Lifting cylinder; 103. Servo motor; 104. Base plate; 105. Baffle mechanism; 106. Tape; 107. Coupling; 2. Upper module mechanism; 201. Mechanism base; 202. X-axis module; 203. Z-axis module; 204. Tool positioning mechanism; 2041. Main connecting plate; 2042. First positioning block; 2043. Pressure sensor; 2044. Second positioning block; 2045. Spring assembly; 205. CCD detection mechanism; 2051. Second main connecting plate; 2052. CCD 2053. Lens; 206. Light source; 207. First slide rail; 208. First slider; 209. Second slide rail; 210. Auxiliary X-axis module; 211. Fourth slide rail; 212. Fourth slider; 213. Scratching tool; 3. Lower module mechanism; 301. Y-axis module; 302. Motor mounting bracket; 303. First rotary motor; 3031. First rotary assembly; 304. Second rotary motor; 3041. Second rotary assembly; 305. Product fixture platform; 306. Third slide rail; 307. Third slider; 4. Equipment platform; 5. Touch screen. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0020] like Figures 1-8 As shown, the present invention discloses an integrated five-axis automatic scratch testing system, comprising a device platform 4 and a tape testing mechanism 1, an upper module mechanism 2, and a lower module mechanism 3 disposed on the device platform 4, wherein: The tape testing mechanism 1 is used to perform adhesion tests on products after the marking process is completed. The upper module mechanism 1 is used to provide X-direction and Z-direction movement for the scratching tool 213 and to perform product photography and inspection. The lower module mechanism is used to move the product fixture platform in the Y direction and to rotate the product fixture platform horizontally and flip it at a predetermined angle; the automatic testing system also includes a PLC control system.

[0021] The specific connection structure is as follows: The tape testing mechanism 1 includes a support column 101, a lifting cylinder 102, a servo motor 103, a base plate 104, a baffle mechanism 105, and a tape 106. The support column 101 is mounted on the equipment platform 4, the lifting cylinder 102 is mounted on the support column 101, and the base plate 104 is connected above the lifting cylinder 102. The baffle mechanism 105 is mounted on the base plate 104. The servo motor 103 and the tape 106 are respectively mounted on both sides of the baffle mechanism 105 and connected by a coupling 107. The servo motor 103 is used to unfold the tape 106.

[0022] The upper module mechanism 2 includes a mechanism base 201, an X-axis module 202, a Z-axis module 203, a tool positioning mechanism 204, and a CCD detection mechanism 205. The mechanism base 201 is positioned on the equipment platform 4. The X-axis module 202 is provided on the mechanism base 201. The X-axis module 202 is provided with a first slide rail 206 and a cooperating first slider 207. The Z-axis module 203 is fixedly provided on the first slider 207. The Z-axis module 203 is provided with a second slide rail 208 and a cooperating second slider 209. The tool positioning mechanism 204 is provided on the second slider 209. The CCD detection mechanism 205 is fixedly connected to the tool positioning mechanism 204.

[0023] An auxiliary X-axis module 210 is provided below the X-axis module 202 to make the positioning more secure. The auxiliary X-axis module 210 is provided with a fourth slide rail 211 and a cooperating fourth slider 212. The Z-axis module 203 is fixedly connected to the fourth slider 212 to achieve synchronous movement with the first slider 207.

[0024] The tool positioning mechanism 204 includes a main connecting plate 2041, a first positioning block 2042, a pressure sensor 2043, and a second positioning block 2044. The back of the main connecting plate 2041 is fixedly connected to the second slider 209. A guide rail is provided on the front of the main connecting plate 2041. The first positioning block 2042 and the second positioning block 2044 are disposed on the guide rail. The first positioning block 2042 is disposed at the top of the guide rail and is positioned to the top of the main connecting plate 2041 by a spring assembly 2045. The second positioning block 2044 is disposed at the lower end of the guide rail. The pressure sensor 2043 is disposed between the first positioning block 2042 and the second positioning block 2044 and is connected to the first positioning block 2042. A scratching tool 213 is disposed on the second positioning block 2044. During operation, the pressure sensor 2043 can provide real-time feedback on the force value when it is squeezed, and can adjust the applied force value in real time according to the scratching effect.

[0025] The CCD detection mechanism 205 includes a second main connecting plate 2051 and a CCD lens 2052 and a light source 2053 disposed on the second main connecting plate 2051. The light source 2053 is located below the CCD lens 2052. The second main connecting plate 2051 is fixedly connected to the main connecting plate 2041 of the tool positioning mechanism 204.

[0026] The lower module mechanism 3 includes a Y-axis module 301, a motor mounting bracket 302, a first rotary motor 303, a second rotary motor 304, and a product fixture platform 305. The Y-axis module 301 is fixed on the equipment platform 4. A third slide rail 306 and a cooperating third slider 307 are provided on the Y-axis module 301. The motor mounting bracket 302 is mounted on the third slider 307. The first rotary motor 303 is mounted on the motor mounting bracket 302 and connected to the product fixture platform 305 through a first rotating component 3031, enabling the product fixture platform 305 to rotate at a predetermined angle (suitable for scratches on curved products). The second rotary motor 304 is located below the product fixture platform 305 and connected to the fixture platform through a second rotating component 3041, enabling the product fixture platform 305 to rotate at any angle within the plane.

[0027] The tape testing mechanism 1 is set at a predetermined distance in front of the product fixture platform 305 along the Y-axis module 301 direction. The height of the tape 103 is higher than the height of the product fixture platform 305, and it is used to perform adhesive tests on the scratched product.

[0028] The PLC control system is electrically connected to the X-axis module 202, Y-axis module 301, Z-axis module 203, tape testing mechanism 1, CCD detection mechanism 205, and pressure sensor 2043, respectively, for automating the entire system, including X, Y, and Z displacement movement, tape adhesion testing, CCD image detection, and pressure feedback adjustment. A touchscreen 5 is also provided on the equipment platform 4 for operation and settings.

[0029] The integrated five-axis automatic scratch testing system of the present invention operates as follows: The sample to be tested (a planar product) is fixed on the product fixture platform 305 by heating and cooling with paraffin wax. Pressure parameters are set, and the initial scratch position is determined by adjusting the X-axis module 202 and the Y-axis module 301. The Z-axis module 203 is moved down so that the scratching tool 213 contacts the sample to be tested, initiating the first scratch along the X-axis module 202. After the first scratch is completed, the scratching tool 213 moves along the Z-axis module 202... 03. Move upwards, return to position along the X-axis module 202, and after the product fixture platform 305 moves a predetermined distance along the Y-axis module 301, the Z-axis module 203 moves downwards, causing the scratching tool 213 to contact the sample to be tested and start the second scratch. Repeat the above process to complete all transverse scratches. Then, the second rotary motor 304 runs and controls the product fixture platform 305 to rotate 90° in a plane angle through the second rotary component 3041, repeating the above transverse scratching process steps to complete the transverse and longitudinal scratching test of the entire product. Then, the Y-axis module 301 moves, causing the product fixture platform 305 to move below the tape 106 of the tape testing mechanism 1. The lifting cylinder 102 operates, driving the tape 106 down onto the product fixture platform 305. The sample after the marking is completed is then glued and peeled off. Afterward, the Y-axis module 301 moves back to its initial position, and the CCD lens 2052 takes a picture of the sample after the glue has been peeled off. The system automatically judges the glue peeling situation and automatically identifies the peeling area, thereby judging the adhesion of the product coating or plating.

[0030] The following criteria can be used as a reference for judgment: 1. Grade 5B: The edges of the cut are completely smooth, and there is no peeling at the edges of the grid. 2. Grade 4B: Small pieces peel off at the intersection of the cuts, and the actual damage within the gridded area is ≤5%; 3. Grade 3B: The edges and / or intersections of the incision are peeled off, with an area greater than 5% to 15%; 4. Grade 2B: Partial or large-scale peeling along the cut edge, or partial peeling of some grids, with the peeled area exceeding 15% to 35%; 5. Grade 1B: Large areas of the cut edge are peeled off / or some squares are partially or completely peeled off, with the area being greater than 35% to 65% of the grid area; 6. Grade 0B: Large areas of peeling at the cut edge are more severe than in Grade 1B, with the area exceeding 65% of the gridded area; The above ratings are as follows Figure 9 As shown, Grade 5B and Grade 4B are considered qualified products, while the rest are unqualified products.

[0031] When it is necessary to perform scratch testing on curved products, other processes are similar to those for flat products. The difference is that the angle information of the curved product is input into the control system. During the scratching operation, the first rotary motor 303 runs and controls the product fixture platform 305 to rotate at a predetermined angle [5° step] through the first rotary component 3031, so as to achieve scratching of the XY plane and space within the angle range of 0-25°.

[0032] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An integrated five-axis automatic scratch testing system, characterized in that, The system includes an equipment platform (4) and a tape testing mechanism (1), an upper module mechanism (2), and a lower module mechanism (3) mounted on the equipment platform (4). The tape testing mechanism (1) is used to perform adhesion testing on the product after the scribing process is completed. The upper module mechanism (2) is used to move the scribing tool (213) in the X and Z directions and to take pictures of the product for inspection. The lower module mechanism (3) is used to move the product fixture platform (305) in the Y direction and to rotate the product fixture platform (305) at a predetermined angle. The automatic testing system also includes a PLC control system. The tape testing mechanism (1) includes a support column (101), a lifting cylinder (102), a servo motor (103), a base plate (104), a baffle mechanism (105), and a tape (106). The support column (101) is set on the equipment platform (4), the lifting cylinder (102) is set on the support column (101), and the base plate (104) is connected above the lifting cylinder (102). The baffle mechanism (105) is set on the base plate (104). The servo motor (103) and the tape (106) are respectively set on both sides of the baffle mechanism (105) and connected by a coupling (107). The servo motor (103) is used to realize the unfolding of the tape (106). The upper module mechanism (2) includes a mechanism base (201), an X-axis module (202), a Z-axis module (203), a tool positioning mechanism (204), and a CCD detection mechanism (205). The mechanism base (201) is positioned on the equipment platform (4). The X-axis module (202) is provided on the mechanism base (201). The X-axis module (202) is provided with a first slide rail (206) and a cooperating first slider (207). The Z-axis module (203) is fixedly provided on the first slider (207). The Z-axis module (203) is provided with a second slide rail (208) and a cooperating second slider (209). The tool positioning mechanism (204) is provided on the second slider (209). The CCD detection mechanism (205) is fixedly connected to the tool positioning mechanism (204). The lower module mechanism (3) includes a Y-axis module (301), a motor mounting bracket (302), a first rotary motor (303), a second rotary motor (304), and a product fixture platform (305). The Y-axis module (301) is fixed on the equipment platform (4). A third slide rail (306) and a cooperating third slider (307) are provided on the Y-axis module (301). The motor mounting bracket (302) is set on the third slider (307). The first rotary motor (303) is set on the motor mounting bracket (302) and connected to the product fixture platform (305) through a first rotating component (3031), which can realize the front and rear predetermined angle flipping of the product fixture platform (305). The second rotary motor (304) is set below the product fixture platform (305) and connected to the product fixture platform (305) through a second rotating component (3041), which can realize the rotation of the product fixture platform (305) at any angle in the plane.

2. The integrated five-axis automatic scratch testing system according to claim 1, characterized in that, An auxiliary X-axis module (210) is provided below the X-axis module (202). The auxiliary X-axis module (210) is provided with a fourth slide rail (211) and a cooperating fourth slider (212). The Z-axis module (203) is fixedly connected to the fourth slider (212) to achieve synchronous movement with the first slider (207).

3. The integrated five-axis automatic scratch testing system according to claim 1, characterized in that, The tool positioning mechanism (204) includes a main connecting plate (2041), a first positioning block (2042), a pressure sensor (2043), and a second positioning block (2044). The back of the main connecting plate (2041) is fixedly connected to the second slider (209). A guide rail is provided on the front of the main connecting plate (2041). The first positioning block (2042) and the second positioning block (2044) are provided on the guide rail. The first positioning block (2042) is provided at the top of the guide rail and is positioned at the top of the main connecting plate (2041) by a spring assembly (2045). The second positioning block (2044) is provided at the lower end of the guide rail. The pressure sensor (2043) is provided between the first positioning block (2042) and the second positioning block (2044) and is connected to the first positioning block (2042). A scratching tool (213) is provided on the second positioning block (2044).

4. The integrated five-axis automatic scratch testing system according to claim 3, characterized in that, The CCD detection mechanism (205) includes a second main connecting plate (2051) and a CCD lens (2052) and a light source (2053) disposed on the second main connecting plate (2051). The light source (2053) is located below the CCD lens (2052). The second main connecting plate (2051) is fixedly connected to the main connecting plate (2041) of the tool positioning mechanism (204).

5. The integrated five-axis automatic scratch testing system according to claim 1, characterized in that, The tape testing mechanism (1) is set at a predetermined distance in front of the product fixture platform (305) along the Y-axis module (301) direction, and the height of the tape (106) is higher than the height of the product fixture platform (305).

6. The integrated five-axis automatic scratch testing system according to claim 1, characterized in that, The PLC control system is electrically connected to the X-axis module (202), Y-axis module (301), Z-axis module (203), tape testing mechanism (1), CCD detection mechanism (205) and pressure sensor (2043) respectively, and is used to realize automated control of the entire system.

7. The integrated five-axis automatic scratch testing system according to claim 1, characterized in that, The device platform (4) is also equipped with a touch screen (5).

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