Device and method for detecting passivation performance of oxide layer of copper bar

Abstract

The invention relates to an automatic detection device and method for detecting passivation performance of a copper bar oxide layer. The device is controlled by a central control module and comprises a detection base, a servo motor, an air cylinder, an NFC reader, a scanning electron microscope (SEM), an energy dispersive X-ray spectrum (EDS) and the like. The copper bar body is placed in the detection base with caulking grooves, and each caulking groove is provided with an NFC label used for identifying the position of the copper bar. During detection, the servo motor drives the detection base to move step by step, so that the copper bar main body is detected twice through the first electron microscope camera and the second electron microscope camera in sequence. The system identifies copper bar information through an NFC reader, collects a microstructure image of a copper bar oxide layer through an SEM, and carries out component analysis by using an EDS. The central control module compares the two detection data, and if the results are qualified, the detection is passed; and if not, the system gives an alarm. According to the invention, automatic and accurate detection of the passivation performance is realized, and the detection efficiency, precision and traceability are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of material detection, and in particular to a device and method for detecting passivation performance of an oxide layer of a copper busbar. Background Art

[0002] In the application of copper busbars, the passivation treatment of the surface oxide layer is crucial to improve its corrosion resistance and extend its service life. The passivation layer can effectively prevent the oxidation and corrosion of the copper busbar in a complex environment, thereby ensuring the stable operation of electrical equipment. However, in the actual production process, the quality and performance of the passivation layer may be affected by many factors, such as uneven passivation treatment, insufficient oxide layer thickness or substandard composition. Therefore, how to efficiently and accurately detect the passivation performance of the oxide layer on the surface of the copper busbar has become a technical problem that needs to be solved in the production process.

[0003] Traditional copper busbar passivation performance testing mostly relies on manual observation and single testing equipment, such as microscopes and thickness gauges, which is not only time-consuming and labor-intensive, but also easily affected by human subjective judgment, resulting in inconsistent test results. In addition, a single testing method is difficult to fully evaluate the microstructure and chemical composition of the passivation layer, and cannot ensure that the quality of the passivation layer fully meets the requirements. Therefore, it is particularly important to develop an automated, high-precision passivation performance testing solution that can combine multiple analytical methods.

[0004] Existing detection technologies such as scanning electron microscopy (SEM) can effectively observe the microstructure of the copper busbar surface, and energy dispersive X-ray spectroscopy (EDS) can analyze the chemical composition of the passivation layer. However, the need to combine these technologies and realize automated operation to further improve detection efficiency and accuracy has promoted the innovation of related technologies. By combining NFC tags, automated control systems, and the coordinated use of electron microscopes and EDS, comprehensive detection of copper busbar passivation performance can be achieved, providing higher reliability and traceability, reducing human errors, and improving detection quality. This provides technical support for quality control and product reliability of copper busbar production. Summary of the invention

[0005] The present invention provides an automated detection device for detecting the passivation performance of the copper busbar oxide layer and an operation method thereof. The system combines a variety of advanced technologies, including an automated control system, NFC tag recognition, scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) analysis, and can achieve accurate detection and composition analysis of the copper busbar oxide layer surface morphology, thereby comprehensively evaluating the performance of the passivation layer. The coordinated work of each component is uniformly controlled by a central control module to achieve an efficient and automated detection process, significantly improving the accuracy, efficiency and traceability of the detection.

[0006] 1. Technical solution overview

[0007] The technical solution of the invention mainly includes a detection system, in which the copper busbar body is placed on a detection base with a groove. The top of the detection base is provided with multiple grooves, each of which is provided with a copper busbar body and a corresponding NFC tag for marking the position and number of each copper busbar.

[0008] The system can realize multi-stage and multi-angle inspection of the copper busbar body by controlling the precise coordination of the cylinder, servo motor and electron microscope camera. The serial number information of each copper busbar body is read by the NFC reader. Combined with the imaging and analysis technology of SEM and EDS, the system can observe the microstructure of the oxide layer on the surface of the copper busbar and obtain the chemical composition of the passivation layer through component analysis.

[0009] The detection system is equipped with two sets of electron microscope cameras and controllers, which conduct two tests on each copper busbar body, and compare the two test results to ensure the comprehensiveness and accuracy of the test. If the test results meet the predetermined standards, the passivation performance is determined to be qualified; otherwise, the system marks the unqualified products and issues an alarm message.

[0010] 2. Specific workflow

[0011] Copper busbar loading: Place the copper busbar to be tested in the slot of the test base. The NFC tag in the slot corresponds to each copper busbar and marks its position number for subsequent automatic identification.

[0012] First testing phase:

[0013] The central control module controls the servo motor to drive the detection base to move, so that the copper bar body moves to the detection position of the first electron microscope camera in sequence.

[0014] When the copper busbar is moved into position, the first NFC reader reads the NFC tag to confirm the number and position of the copper busbar to prevent the copper busbar body from being misplaced.

[0015] The control cylinder lowers the first electron microscope controller and the camera to the detection position, and the camera starts to detect the surface morphology of the oxide layer on the surface of the copper busbar.

[0016] At the same time, the composition of the passivation layer is preliminarily analyzed through the EDS system to determine the main elements and distribution in the passivation layer.

[0017] Second testing phase:

[0018] The central control module controls the servo motor to move the detection base again, and moves the copper busbar body to the detection position of the second electron microscope camera.

[0019] The second NFC reader reads the NFC tag to confirm that the detected subject is the same object as the copper busbar detected for the first time.

[0020] The control cylinder lowers the second electron microscope controller and camera to conduct secondary surface morphology and composition inspection. By comparing with the first inspection results, the performance of the passivation layer is further verified.

[0021] Data analysis and result determination:

[0022] The central control module compares and analyzes the data from the two tests (including the morphological image and component analysis results). If both test results meet the standards, the copper busbar is qualified; if any test result fails, the system determines that the copper busbar is unqualified and marks it.

[0023] Data storage and alarm mechanism:

[0024] The central control module stores the inspection data of each copper busbar in the database to ensure the traceability and quality management of the inspection data. If there are unqualified products, the system automatically generates an alarm to prevent unqualified products from entering the subsequent production links.

[0025] 3. Composition and working principle of the central control module

[0026] The central control module is the core control unit of the entire system, responsible for coordinating the operation of various electrical devices, including servo motors, cylinders, electron microscope cameras, EDS analysis systems, NFC readers, etc. The module communicates with these devices through pulses or digital signals to ensure the precise execution of each step.

[0027] The data acquisition module is responsible for acquiring the test data from the electron microscope camera and the EDS system and preprocessing the data. The preprocessed data is analyzed by the data processing unit, including image analysis of the surface morphology and comparative analysis of the passivation layer composition.

[0028] The servo motor drive control module controls the stepping motion of the detection base, moving each copper bar to the detection position in turn.

[0029] The cylinder control module controls the lifting and lowering of the electron microscope camera to ensure that the camera can be aimed at the surface of the copper busbar to obtain a clear inspection image.

[0030] The storage module is responsible for storing the results of each test in the system database to ensure the traceability of all test data.

[0031] The alarm and feedback module automatically issues alarm information based on the test results, marks unqualified products, and transmits feedback information to the production management system.

[0032] Beneficial effects of the present invention:

[0033] 1. This technical solution achieves efficient and accurate detection of the passivation performance of the copper busbar oxide layer through an automated control system combined with NFC tags, scanning electron microscopes (SEM) and energy dispersive X-ray spectroscopy (EDS) technology. The system adopts a dual detection mechanism and real-time data feedback to ensure the accuracy and reliability of the test results. It also has a modular design for easy expansion and maintenance. Through automated operation, human errors are reduced, data traceability and real-time alarms are achieved, and detection efficiency and quality control levels are greatly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings in the following description are only for the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0035] Figure 1 It is a schematic diagram of the three-dimensional structure of an embodiment of the present invention;

[0036] Figure 2 is a side view schematic diagram of an embodiment of the present invention;

[0037] Figure 3 A schematic top view of an embodiment of the present invention;

[0038] Figure 4 A schematic top view of an embodiment of the present invention;

[0039] Figure 5 A schematic diagram of a slide drive structure according to an embodiment of the present invention;

[0040] Figure 6 This is a schematic diagram of the installation structure of the electron microscope camera and the NFC reader according to an embodiment of the present invention;

[0041] Figure 7 Schematic diagram of the detection process of an embodiment of the present invention.

[0042] The markings in the figure are:

[0043] 1. Workbench; 2. Column; 3. Crossbeam; 4. Cylinder; 5. Mounting seat; 6. First electron microscope controller; 7. First electron microscope camera; 8. Guide seat; 9. Slide rod; 10. Sleeve seat; 11. Detection base; 12. Embossed groove; 13. Copper busbar body; 14. NFC tag; 15. Central control module; 16. Slide seat; 17. Guide rail; 18. Servo motor; 19. Connecting seat; 20. Lead screw; 21. Bearing seat; 22. Second electron microscope controller; 23. Second electron microscope camera; 24. First NFC reader; 25. Second NFC reader. DETAILED DESCRIPTION

[0044] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with specific embodiments.

[0045] Detailed description of the copper busbar oxide layer passivation performance test process

[0046] Preparation:

[0047] Place the copper busbars to be tested into the slots of the testing base in sequence according to their numbers. Each slot is pre-installed with a corresponding NFC tag to mark the location information of different copper busbars, such as "first copper busbar", "second copper busbar", etc.

[0048] The central control module is initialized and ensures that all electrical devices such as servo motors, control cylinders, electronic mirror cameras, NFC readers, etc. are properly connected and ready.

[0049] First stage testing:

[0050] The first electron microscope camera makes initial observation: the central control module controls the servo motor to drive the detection base to start moving, and moves the embedding groove for placing the copper bar to the bottom of the first electron microscope controller and the first electron microscope camera in sequence.

[0051] NFC reading and identification: When the copper busbar body reaches the first detection position, the first NFC reader reads the information of the NFC tag in the slot and identifies the position and number of the current copper busbar, such as "the first copper busbar".

[0052] Surface morphology observation: The first electron microscope camera observes the surface of the copper busbar, collects the microscopic morphology of the oxide layer, and checks whether there are defects such as cracks, holes, unevenness, etc. on the surface.

[0053] EDS analysis: The first electron microscope system is used in conjunction with the EDS energy dispersive X-ray spectrum to perform surface composition analysis, determine the main element composition in the oxide layer and passivation layer, and detect the element content and distribution of the passivation layer.

[0054] Data transmission and preliminary detection: The data of the initial detection, including the surface morphology image and EDS analysis results, are transmitted to the system database for storage through the central control module, and a preliminary judgment on the passivation performance of the oxide layer is made.

[0055] Second stage testing:

[0056] Stepping motion: The central control module controls the servo motor to drive the detection base to perform precise stepping motion, moving the copper bar body to under the second electron microscope controller and the second electron microscope camera.

[0057] Second NFC reading: The second NFC reader reads the information of the NFC tag again to confirm the number and location information of the copper busbar body to ensure that it is consistent with the copper busbar detected in the first test.

[0058] Surface morphology observation and EDS analysis: Similar to the first stage, the second electron microscope camera conducts a second observation of the surface of the copper busbar to collect more surface morphology data; at the same time, EDS is used to perform surface composition analysis again to verify whether the composition and distribution of the passivation layer meet the requirements.

[0059] Data comparison and analysis: The central control module collects the secondary test data and compares and analyzes it with the first test results, focusing on checking whether there are any changes on the surface of the passivation layer, such as new defects or inconsistent components.

[0060] Test result determination:

[0061] The central control module will conduct a comprehensive comparison of the results of the two tests. If both test results meet the predetermined standards, the copper busbar is considered to have passed the main body test and the next copper busbar will be tested. If any of the test results are unqualified, the copper busbar main body test fails and the system will mark the unqualified copper busbar for further processing.

[0062] Automated recording and processing:

[0063] After the test is completed, the central control module records all the test data in the system database, including the number of each copper bar, the test time, the test results, etc. If the test fails, the system will automatically generate an alarm message and may send it to the corresponding processing module to arrange for rework or removal of the unqualified products.

[0064] Operation process and structure of the central control module

[0065] Composition structure

[0066] Main control unit MCU: As the core controller, it is responsible for the overall process control and logic operation. It receives signals from sensors and devices and sends control instructions.

[0067] Data acquisition module: connected with electron microscope camera, NFC reader, EDS and other devices, responsible for collecting data generated during the detection process, such as surface morphology images, component analysis data, etc.

[0068] Servo motor drive control module: controls the stepping motion of the servo motor to ensure that the detection base moves along the predetermined route, so that the copper busbar body moves accurately to the detection position of the electron microscope controller.

[0069] Control cylinder drive module: The control cylinder drives the vertical lifting of the electron microscope camera system to ensure that it can focus accurately and remain stable during the inspection process.

[0070] Data processing unit: responsible for processing test data, including morphology image processing, component analysis data processing, etc., generating passivation performance test reports, and making qualified or unqualified judgments.

[0071] Storage module: used to store the test data, historical records and test reports of each copper busbar body, which is convenient for later traceability and quality management.

[0072] Communication module: responsible for communication with external devices, including connection with the host computer system, external database, etc., to achieve real-time data transmission and remote monitoring.

[0073] Operation Process

[0074] Initial configuration and test start-up: The central control module performs preliminary configuration by controlling the servo motors and cylinders, confirms that each device is operating normally, and starts the test process.

[0075] Read NFC tag information: When the copper busbar enters the detection position, the central control module obtains the tag information from the NFC reader to determine the current copper busbar number and corresponding position.

[0076] Control the electron microscope camera: Control the electron microscope camera and EDS system to start detection and collect surface morphology images and composition analysis data.

[0077] Data analysis and judgment: Process and analyze the collected data to determine whether the performance of the passivation layer is qualified.

[0078] Control the servo motor: According to the detection progress, control the servo motor to move the detection base so that the copper busbar body enters the detection area of ​​the first and second electron microscope controllers in turn.

[0079] Storage and feedback of test results: Generate and store a complete test report based on the test results; if unqualified products appear, trigger the corresponding alarm or rejection mechanism.

[0080] This solution uses a highly automated central control module combined with SEM, EDS and NFC tags to achieve efficient detection of the passivation performance of the copper busbar oxide layer.

[0081] In the above technical solution, the combined workflow of SEM+EDS is as follows:

[0082] Sample preparation and setup:

[0083] The sample is placed in the SEM vacuum chamber. It is usually necessary to conduct electricity to ensure that the surface does not accumulate charge when the SEM electron beam scans.

[0084] When the SEM starts working, the electron beam scans the sample surface to collect the morphological information of the sample surface.

[0085] Microscopic morphology observation (SEM):

[0086] The electron beam scans the sample surface, creating a high-resolution image.

[0087] Operators can use SEM to observe the surface morphology of samples, such as the passivation layer, cracks, holes and other features on the surface. This helps to evaluate the quality of surface treatment, such as whether the passivation layer is uniform and whether there are surface defects.

[0088] Component analysis (EDS):

[0089] While the SEM is acquiring images, the EDS detector is turned on, capturing the characteristic X-rays produced by the interaction of the electron beam with the sample.

[0090] The EDS detector converts these X-ray signals into an energy distribution diagram (energy spectrum), with each peak corresponding to a different element. By analyzing these peaks, the system can determine the type and content of elements in the sample.

[0091] Analysis and presentation of results:

[0092] SEM provides microstructural images of the surface, while EDS provides the chemical composition distribution of the surface area.

[0093] Operators can evaluate the quality of the passivation layer on the sample surface, such as the uniformity of the oxide layer and the distribution of chemical composition, by comparing SEM images and EDS composition analysis results of different areas.

[0094] 4. Application of SEM+EDS in the detection of passivation performance of copper busbar oxide layer

[0095] In the passivation performance test of the copper busbar oxide layer, the SEM+EDS workflow is as follows:

[0096] Surface morphology observation (SEM): Through SEM scanning, check whether the oxide layer on the surface of the copper busbar is uniform, whether there are defects such as cracks and holes, and evaluate the quality of the passivation layer from a microscopic perspective.

[0097] Chemical composition analysis (EDS): EDS is used to analyze the main elemental components of the passivation layer, such as oxygen, copper, and other compounds that may be formed during the passivation process. Based on the element content and distribution, it is determined whether the passivation layer has good protective properties.

[0098] This combination makes SEM+EDS extremely advantageous in the detection of the passivation performance of the copper busbar oxide layer. It can not only see the surface morphology, but also detect the chemical composition, ensuring that the quality of the passivation layer fully meets the requirements.

[0099] Since SEM and EDS are both existing technologies, the above content describes their working principles without going into details here. The system composition and hardware structures required for their operation are expressed in the above specific implementation methods and will not be described in detail.

[0100] The present invention is intended to cover all such substitutions, modifications and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A copper busbar oxide layer passivation performance detection device, comprising a workbench (1), wherein the top of the workbench (1) is vertically symmetrically provided with columns (2), the top of the columns (2) is laterally provided with a same crossbeam (3), the top of the crossbeam (3) is provided with a cylinder (4), the output end of the cylinder (4) passes through the crossbeam (3), and the end is laterally provided with a mounting seat (5), the top of the workbench (1) is centrally symmetrically provided with a guide rail (17), the top of the guide rail (17) is laterally slidably installed with a same slide seat (16), and the top of the slide seat (16) is provided with a detection base (11), characterized in that: The top of the detection base (11) is provided with a plurality of embedding grooves (12), and a copper bar body (13) can be detachably placed inside the embedding grooves (12). The bottom of the embedding grooves (12) is provided with NFC tags (14), and the NFC tags (14) are used to mark the position information of different copper bars. The two ends of the mounting seat (5) are provided with a first electron microscope controller (6) and a second electron microscope controller (22), respectively. The bottom of the first electron microscope controller (6) is provided with a first electron microscope camera (7), and the bottom of the second electron microscope controller (22) is provided with a second electron microscope camera (23). The side of the first electron microscope camera (7) is provided with a second NFC reader (25), and the side of the second electron microscope camera (23) is provided with a first NFC reader (24). The first NFC reader (24) and the second NFC reader (25) are both used to read the information pre-installed in the NFC tag (14). One side of the workbench (1) is provided with a central control module (15) for controlling the operation of the cylinder (4), the electron microscope camera, and the NFC reader.

2. A copper busbar oxide layer passivation performance detection device according to claim 1, characterized in that: A connecting seat (19) is provided at the bottom of the sliding seat (16), a lead screw (20) is transversely inserted into the connecting seat (19), a servo motor (18) is transversely provided at one end of the lead screw (20), a bearing seat (21) is sleeved at one end of the lead screw (20) away from the servo motor (18), and the bearing seat (21) is fixed to the top of the workbench (1).

3. A copper busbar oxide layer passivation performance detection device according to claim 2, characterized in that: A guide seat (8) is transversely provided at the output end of the cylinder (4), and sliding rods (9) are vertically inserted at both ends of the guide seat (8). The sliding rods (9) are slidably sleeved with sleeve seats (10), and the sleeve seats (10) are respectively fixedly connected to the columns (2) on the adjacent side, and the top of the sliding rod (9) slides through the top of the crossbeam (3).

4. A copper busbar oxide layer passivation performance detection device according to claim 3, characterized in that: The central control module (15) is electrically connected to the servo motor (18) via a PLC control system.

5. A copper busbar oxide layer passivation performance detection device according to claim 4, characterized in that: The central control module (15) controls the gas in and out of the cylinder (4) through the solenoid valve, and the control signal opens or closes the solenoid valve to adjust the movement of the cylinder (4).

6. A copper busbar oxide layer passivation performance detection device according to claim 5, characterized in that: The central control module (15) exchanges data with the first NFC reader (24) and the second NFC reader (25) via a serial communication protocol (I2 C, SPI or UART).

7. A copper busbar oxide layer passivation performance detection device according to claim 6, characterized in that: The central control module (15) communicates with the servo driver via a pulse signal (PWM signal) or a digital signal to control the precise stepping motion of the servo motor (18).

8. A copper busbar oxide layer passivation performance detection device according to claim 7, characterized in that: The central control module (15) communicates with the first electron microscope camera (7) and the second electron microscope camera (23) via USB, LAN, or a dedicated video interface to obtain real-time image data, and controls the focal length of the camera through instructions to ensure that the oxide layer morphology on the surface of the copper busbar body (13) is clearly visible. The central control module (15) automatically or manually adjusts the exposure, contrast and brightness of the camera according to the on-site lighting conditions to obtain the best image quality. The central control module (15) sends instructions to the electron microscope camera to control it to start or stop image acquisition, and transmits the image data to the central control module (15) for subsequent analysis and processing. When the image data captured by the electron microscope camera works in conjunction with the EDS system, the central control module (15) is responsible for coordinating the surface image captured by the camera and the component information analyzed by the EDS to integrate them into a comprehensive detection report.

9. A method for detecting the passivation performance of a copper busbar oxide layer according to any one of claims 1 to 8, characterized in that: The following steps are involved: S1. Preparation: The copper bar bodies (13) to be tested are placed into the embedding grooves (12) of the testing base (11) in sequence according to the numbers. A corresponding NFC tag (14) is pre-installed inside each embedding groove to mark the position information of different copper bars, such as "first copper bar" and "second copper bar". The central control module (15) is initialized and ensures that all electrical equipment (such as servo motors, control cylinders, electronic microscope cameras, NFC readers, etc.) are normally connected and ready; S1. First stage detection: initial observation by the first electron microscope camera (7): the central control module (15) controls the servo motor (18) to drive the detection base (11) to start moving, and the embedding groove for placing the copper bar is moved to the bottom of the first electron microscope controller (6) and the first electron microscope camera (7) in sequence; NFC reading and identification: when the copper bar body (13) reaches the first detection position, the first NFC reader (24) reads the information of the NFC tag (14) in the embedding groove (12) to identify the position and number of the current copper bar (such as "first copper bar"); surface morphology observation: the first electron microscope camera The head (7) observes the surface of the copper busbar, collects the microscopic morphology of the oxide layer, and checks whether there are defects on the surface (such as cracks, holes, unevenness, etc.); EDS analysis: the first electron microscope system is used in conjunction with EDS (energy dispersive X-ray spectroscopy) to perform surface composition analysis, determine the main element composition in the oxide layer passivation layer, and detect the element content and distribution of the passivation layer; data transmission and preliminary detection: the data of the initial detection, including the surface morphology image and the EDS analysis result, are transmitted to the system database for storage through the central control module (15), and a preliminary judgment on the passivation performance of the oxide layer is performed; S3, second stage detection: Stepping motion: the central control module (15) controls the servo motor (18) to drive the detection base (11) to perform precise stepping motion, and moves the copper busbar body (13) to the bottom of the second electron microscope controller (22) and the second electron microscope camera (23); second NFC reading: the second NFC reader (25) reads the information of the NFC tag (14) again, confirms the serial number and position information of the copper busbar body, and ensures that it is consistent with the copper busbar detected for the first time; surface morphology observation and EDS analysis: similar to the first stage, the second electron microscope camera (23) observes the surface of the copper busbar body for the second time and collects more surface morphology data; at the same time, the surface composition analysis is performed again through EDS to verify whether the composition and distribution of the passivation layer meet the requirements; data comparison and analysis: the central control module (15) collects the secondary detection data, compares and analyzes it with the first detection result, and focuses on checking whether the surface of the passivation layer has changed (such as the emergence of new defects or inconsistent composition, etc.); S4, test result determination: the central control module (15) conducts a comprehensive comparison of the results of the two tests; if both test results meet the predetermined standard, the copper bar body test is determined to have passed, and the next copper bar is tested; if any of the test results is unqualified, the copper bar body test fails, and the system marks the unqualified copper bar for further processing; S5. Automated recording and processing: After the test is completed, the central control module (15) records all the test data in the system database, including the number of each copper bar, the test time, the test result, etc. If the test fails, the system will automatically generate an alarm message and may send it to the corresponding processing module to arrange for the unqualified products to be reworked or rejected.

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