Quality inspection device and grade detection method for zinc coating on surface of metal material

Abstract

The invention provides a quality inspection device and grade detection method for a zinc coating on the surface of a metal material, the quality inspection device comprises a composite probe, the composite probe is composed of double sensors integrating a magnetic sensor and an eddy current sensor, the thickness measured by the magnetic sensor is d1, the thickness measured by the eddy current sensor is d2, and a zinc coating quality judgment program carries out data judgment on the d1 and the d2. If d2 is equal to 0, the d1 is compared with the preset qualified range value of the thickness of the zinc coating, if d2 is not equal to 0, the value of d1-d2 is compared with the preset qualified range value of the thickness of the zinc coating, and if the values of d1 and d1-d2 fall into the preset qualified range value of the thickness of the zinc coating, the thickness of the zinc coating is qualified. The grade detection method comprises the following steps: observing the display screen, and obtaining the grade of the zinc coating according to the condition that d2 is equal to 0 and d1 or d2 is not equal to 0 and d1-d2 falls into the grade range of the thickness of the zinc coating. The method has the beneficial effects that whether the galvanized layer of the metal material with the paint layer and the galvanized layer is qualified or not is judged, and the efficiency is improved. The device is light in structure, convenient to carry, suitable for field operation, capable of obtaining results in seconds and high in detection speed.

Description

Technical Field

[0001] The present invention relates to the technical field of coating and plating layer detection, and in particular to a quality inspection device and a grade detection method for a zinc plating layer on a metal material surface. Background Art

[0002] In the industrial production process, accurate detection of material thickness is a key step to ensure that product quality meets standards. In order to prevent corrosion of metal materials, paint is often sprayed on their surfaces or hot-dip galvanized. The spray coating or galvanized layer formed in this way can effectively isolate the metal material from the external environment, thereby achieving the purpose of corrosion prevention. For steel components of power grid equipment, the relevant standards clearly stipulate the anti-corrosion thickness of the galvanized layer. For production and processing, in order to meet the deadline, there may be different batches of galvanized steel parts that do not meet the thickness requirements, or there may be a layer of paint with a color similar to the galvanized layer on the galvanized layer, which is inferior to good. For product purchasers, random inspection of products will not be conducted, and each product cannot be accurately and quickly inspected by the naked eye or thickness gauge alone. Therefore, if the construction party can have a fast and miniaturized detection device, each galvanized steel part can be tested in seconds before construction and installation, and each piece can be tested before installation. Therefore, it is necessary to design such a device. Summary of the invention

[0003] The purpose of the present invention is to provide a quality inspection device for a zinc-plated layer on the surface of a metal material, and at the same time to provide a grade inspection method for an anti-corrosion layer coated on a metal material.

[0004] The technical solution of the present invention is as follows: a quality inspection device for the zinc-plated layer on the surface of a metal material, comprising a composite probe, the composite probe being a dual sensor composed of an integrated magnetic sensor and an eddy current sensor, the composite probe and a host unit being of a separate type, connected by a wire with a plug when in use, the host unit being arranged in a casing, the casing having a power module and a calibration module, the power module providing electric energy for electrical components, a display screen and buttons being embedded on the surface of the casing, the host unit being connected to the display screen and control buttons by wires; The host unit receives thickness data from the composite probe, the thickness measured by the magnetic sensor is d1, and the thickness measured by the eddy current sensor is d2. The host unit includes a data processing module, and the data processing module is provided with a galvanized layer quality judgment program. The galvanized layer quality judgment program performs data judgment and comparison on d1 and d2. If d2=0, d1 is compared with a preset galvanized layer thickness qualified range value. If d1 falls within the preset galvanized layer thickness qualified range, a galvanized layer thickness qualified signal is output, otherwise an unqualified signal is output and displayed on a display screen; if d2≠0, the value of d1-d2 is compared with a preset galvanized layer thickness qualified range value. If the value of d1-d2 falls within the preset galvanized layer thickness qualified range, a galvanized layer thickness qualified signal is output, otherwise an unqualified signal is output and displayed on a display screen.

[0005] Furthermore, the host unit is also provided with a storage module, which is used to store d1, d2, test time and remarks, and the remarks are inputted by using a key and a display screen.

[0006] Furthermore, a calibration module is also provided in the housing, and the calibration module is electrically connected to the host unit. The calibration module is used to perform temperature compensation on the magnetic sensor and the eddy current sensor and calibrate the data.

[0007] The data processing module includes a signal amplifying circuit, a filtering circuit and a microprocessor. The signal amplifying circuit is used to enhance the sensor signal, the filtering circuit is used to filter out the noise signal, and the microprocessor is used to perform data analysis and calculation.

[0008] Furthermore, the casing is provided with a heat dissipation port, the power module is a replaceable battery, and is provided with a voltage stabilizing circuit.

[0009] Furthermore, the host unit is also provided with a galvanized layer judgment module, which has a built-in galvanized layer magnetic sensor signal standard. The galvanized layer judgment module receives the signal of the magnetic sensor and compares it with the built-in galvanized layer magnetic sensor signal standard. If it meets the requirements, it is judged to contain a galvanized layer.

[0010] A method for detecting the grade of a zinc-plated layer on the surface of a metal material, using a quality inspection device for the zinc-plated layer on the surface of a metal material to test the coating layer on the surface of the metal material, if it is a zinc-plated layer and a qualified signal for the zinc-plated layer thickness is obtained, the data d1 and d2 on the display screen are observed, and the grade of the zinc-plated layer on the surface of the metal material is obtained when d2=0, d1 value or d2≠0, d1-d2 value falls within the grade range of the zinc-plated layer thickness.

[0011] The beneficial effects of the present invention are as follows: the present invention can measure the thickness of the coating layer of metal materials with paint layers and galvanized layers, obtain the result of whether the galvanized layer is qualified, and improve the detection efficiency. The split design allows the probe to be flexibly replaced to meet the needs of different detection scenarios. The data processing module ensures the accuracy of the measurement results, and the calibration module reduces the impact of environmental factors. The intuitive operation interface and clear display reduce the difficulty of user operation. The structure is light and easy to carry, and it can be used in field operations. Each galvanized steel part before construction is tested to see if it is qualified, and the speed is fast, and the results are obtained in seconds, and the detection time does not delay the construction progress. At the same time, the grade of the anti-corrosion coating of the metal material can also be obtained. For metal materials with both paint layers and galvanized layers on the surface, they can also be used according to the measured grade to avoid material waste. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a structural schematic diagram of the device of the present invention; Figure 2 It is a schematic diagram of the workflow of the present invention. DETAILED DESCRIPTION

[0013] A quality inspection device for zinc-plated layer on the surface of metal materials, comprising a housing, a composite probe, a host unit, a power module, a display screen, etc. The composite probe is composed of a dual sensor integrating a magnetic sensor and an eddy current sensor. The composite probe and the host unit are split and connected by a wire with a plug when in use. The host unit is arranged in the housing, and a power module and a calibration module are arranged in the housing. The power module provides power to the electrical components. A display screen and buttons are embedded on the surface of the housing. The host unit is connected to the display screen and control buttons by wires.

[0014] The host unit receives thickness data from the composite probe. The thickness measured by the magnetic sensor is d1, and the thickness measured by the eddy current sensor is d2. The host unit includes a data processing module, including a signal amplification circuit, a filtering circuit and a microprocessor. The signal amplification circuit is used to enhance the sensor signal, the filtering circuit is used to filter out the noise signal, and the microprocessor is used to perform data analysis and calculation. The microprocessor is provided with a galvanized layer quality judgment program, and the galvanized layer quality judgment program performs data judgment and comparison on d1 and d2. If d2=0, d1 is compared with the preset galvanized layer thickness qualified range value. If d1 falls into the preset galvanized layer thickness qualified range, a galvanized layer thickness qualified signal is output, otherwise an unqualified signal is output and displayed on the display screen; if d2≠0, the value of d1-d2 is compared with the preset galvanized layer thickness qualified range value. If the value of d1-d2 falls into the preset galvanized layer thickness qualified range, a galvanized layer thickness qualified signal is output, otherwise an unqualified signal is output and displayed on the display screen.

[0015] How to use the device: First turn on the machine for preheating, then place the composite probe on the surface of the magnetic matrix metal material to be measured. The thickness measured by the magnetic sensor and the thickness measured by the eddy current sensor form an electrical signal. The electrical signal is transmitted to the data processing module of the host unit through a wire, and the signal amplification circuit amplifies the weak signal from the sensor to improve the signal-to-noise ratio of the signal. Then, the filter circuit filters the amplified signal to remove noise and interference signals and retain useful measurement signals. Finally, the microprocessor performs high-speed data acquisition and calculation processing on the filtered signal to obtain a signal indicating whether the galvanized layer thickness is qualified, and sends these data signals to the display screen for real-time display.

[0016] Furthermore, the host unit is provided with a storage module, which is used to store d1, d2, test time and notes, and the notes are input by keys and display screen. The storage module can be a storage card, or a data output port can be set to import data into a computer for viewing using a data cable. At the same time, the device also has a historical data viewing function, which can call up data through keys and display screen to display previous test records.

[0017] Furthermore, a calibration module is also provided in the housing, and the calibration module is electrically connected to the host unit. The calibration module is used to perform temperature compensation on the magnetic sensor and the eddy current sensor, and to calibrate the data received by the host unit.

[0018] Furthermore, the housing is provided with heat dissipation ports, which can provide heat dissipation for the heat generating components when used for a long time. The power module is a replaceable battery and is provided with a voltage stabilizing circuit to provide a stable voltage for the electrical components, especially the sensors, which need a more stable voltage to avoid damage due to unstable voltage.

[0019] Furthermore, the host unit is also provided with a galvanized layer judgment module, which has a built-in galvanized layer magnetic sensor signal standard. The galvanized layer judgment module receives the signal of the magnetic sensor and compares it with the built-in galvanized layer magnetic sensor signal standard. If it meets the requirements, it is judged to contain a galvanized layer.

[0020] A method for detecting the grade of a zinc coating on the surface of a metal material, using a quality inspection device for the zinc coating on the surface of a metal material to test the coating on the surface of the metal material. If it is a zinc coating, and a qualified signal for the zinc coating thickness is obtained, the display screen d1 and d2 data are observed, and the grade of the zinc coating on the surface of the metal material is obtained by the value of d2=0, d1 or d2≠0, d1-d2 falling into the grade range of the zinc coating thickness. The grade range is defined by national standards or industry standards. In this way, even a galvanized component with a paint layer can be used in an occasion suitable for its grade, reducing resource waste.

Claims

1. A quality inspection device for the zinc coating on the surface of a metal material, comprising a composite probe, wherein the composite probe is composed of a dual sensor integrating a magnetic sensor and an eddy current sensor, and is characterized in that: The composite probe and the host unit are separate and connected by a wire with a plug when in use. The host unit is set in a casing, which contains a power module and a calibration module. The power module provides power to the electrical components. A display screen and buttons are embedded on the surface of the casing. The host unit, the display screen and the control buttons are connected by wires. The host unit receives thickness data from the composite probe, the thickness measured by the magnetic sensor is d1, and the thickness measured by the eddy current sensor is d2. The host unit includes a data processing module, and the data processing module is provided with a galvanized layer quality judgment program. The galvanized layer quality judgment program performs data judgment and comparison on d1 and d2. If d2=0, d1 is compared with a preset galvanized layer thickness qualified range value. If d1 falls within the preset galvanized layer thickness qualified range, a galvanized layer thickness qualified signal is output, otherwise an unqualified signal is output and displayed on a display screen; if d2≠0, the value of d1-d2 is compared with a preset galvanized layer thickness qualified range value. If the value of d1-d2 falls within the preset galvanized layer thickness qualified range, a galvanized layer thickness qualified signal is output, otherwise an unqualified signal is output and displayed on a display screen.

2. The quality inspection device for the zinc coating on the surface of a metal material according to claim 1, characterized in that: The host unit is also provided with a storage module, which is used to store d1, d2, test time and remarks, and the remarks are inputted by using a key and a display screen.

3. The quality inspection device for the zinc coating on the surface of a metal material according to claim 1, characterized in that: A calibration module is also provided in the housing, and the calibration module is electrically connected to the host unit. The calibration module is used to perform temperature compensation on the magnetic sensor and the eddy current sensor and calibrate the data.

4. The quality inspection device for the zinc coating on the surface of a metal material according to claim 1, characterized in that: The data processing module includes a signal amplifying circuit, a filtering circuit and a microprocessor. The signal amplifying circuit is used to enhance the sensor signal, the filtering circuit is used to filter out the noise signal, and the microprocessor is used to perform data analysis and calculation.

5. The quality inspection device for the zinc coating on the surface of a metal material according to claim 1, characterized in that: The casing is provided with a heat dissipation vent, the power module is a replaceable battery, and is provided with a voltage stabilizing circuit.

6. The quality inspection device for the zinc coating on the surface of a metal material according to claim 1, characterized in that: The host unit is also provided with a galvanized layer judgment module, which has a built-in galvanized layer magnetic sensor signal standard. The galvanized layer judgment module receives the signal of the magnetic sensor and compares it with the built-in galvanized layer magnetic sensor signal standard. If it meets the requirements, it is judged to contain a galvanized layer.

7. A method for detecting the grade of a zinc coating on a metal surface, characterized in that: Use the quality inspection device for the zinc-plated layer on the surface of a metal material of claim 6 to test the coating layer on the surface of the metal material. If it is a zinc-plated layer and a qualified signal of the zinc-plated layer thickness is obtained, observe the data d1 and d2 on the display screen. When d2=0, d1 value or d2≠0, d1-d2 value falls within the grade range of the zinc-plated layer thickness, the grade of the zinc-plated layer on the surface of the metal material can be obtained.

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