Wear detection device for bare board thermal forming die

Abstract

The invention discloses a bare board thermal forming mold wear detection device, and relates to the technical field of mold detection, the bare board thermal forming mold wear detection device comprises an upper mold plate and a lower mold plate which are symmetrically arranged, and a telescopic cylinder is arranged between the upper mold plate and the lower mold plate; the upper die holder is fixed below the upper die plate; the lower die base is fixed above the lower die plate, a lower die wedge block is arranged in the lower die base, and a cooling system is further arranged on the lower die base; the detection assembly is arranged between the upper mold plate and the lower mold plate, the detection assembly at least comprises a detection compensation assembly capable of moving transversely and longitudinally, the detection compensation assembly is used for detecting the abrasion loss of a lower mold wedge block and spraying compensation based on the abrasion loss, and online detection and repairing can be achieved through the device.

Description

Technical Field

[0001] This invention relates to the field of mold inspection technology, and specifically to a wear detection device for bare sheet thermoforming molds. Background Technology

[0002] During the service of thermoforming molds for bare sheet metal forming, high-temperature oxides from the bare sheet metal adhere to the rounded corners of the mold. This causes intense friction during the sliding of the sheet metal. With prolonged service, this friction can lead to roughening of the mold, and the on-site grinding of the adhered material can result in geometric defects in the mold, affecting product forming. Therefore, regular mold inspection and repair are necessary.

[0003] Traditional mold maintenance techniques have some limitations. First, existing technologies rely on manual visual inspection or contact measurement after machine shutdown and disassembly, with inspection cycles lasting several hours, making it impossible to capture minute wear and tear during service in real time.

[0004] Secondly, traditional spraying repair uses a single paint and uniform spraying mode, which makes the control of the repair area imprecise. It often results in paint accumulation at the edges or insufficient coverage of key areas, and the surface needs to be ground twice after repair.

[0005] Therefore, it is necessary to provide a device for detecting wear of bare sheet thermoforming molds to solve the above problems. Summary of the Invention

[0006] To solve the above problems, the present invention provides the following technical solution: a bare sheet thermoforming die wear detection device, comprising:

[0007] The upper and lower templates are symmetrically arranged, and a telescopic cylinder is provided between the upper and lower templates;

[0008] The upper mold base is fixed below the upper template.

[0009] A lower mold base is fixed above the lower mold plate. A lower mold wedge is provided in the lower mold base, and a cooling system is also provided on the lower mold base.

[0010] A detection component is disposed between the upper and lower templates. The detection component includes at least a detection compensation component capable of lateral and longitudinal movement. The detection compensation component is used to detect the wear amount of the lower mold wedge and to perform spraying compensation based on the wear amount.

[0011] Furthermore, preferably, the detection component further includes:

[0012] A longitudinal lead screw assembly is disposed between the upper and lower templates and has a longitudinally moving end;

[0013] A track is arranged parallel to each other on one side of the longitudinal lead screw assembly, and a slide block is slidably mounted on it;

[0014] A limiting connecting plate is connected between the longitudinal moving end and the slide, and a limiting groove extending laterally is provided in the middle.

[0015] The detection compensation component is movably disposed below the limiting groove.

[0016] Furthermore, as a preferred embodiment, a lead screw is rotatably provided between the longitudinal moving end and the slide block, the lead screw is driven by a servo motor embedded in the slide block, and the lead screw is also connected to the detection and compensation component.

[0017] Furthermore, as a preferred embodiment, the detection compensation component includes a detection compensation base, and a detection head is provided at each of the four corners of the bottom of the detection compensation base. The four detection heads are, in order, a first visual sensor, a second visual sensor, a third visual sensor, and a structured light emitter, and the four detection heads are equidistant from the center of the bottom of the detection compensation base.

[0018] Furthermore, preferably, the four detection heads are configured such that when the detection compensation assembly moves above the lower mold wedge, the incident angle θ of the structured light emitter is 30±2° with the center normal of the lower mold wedge;

[0019] The first vision sensor is used to cover the left side region of the lower mold wedge block;

[0020] The second vision sensor is used to cover the central area of ​​the lower mold wedge block;

[0021] The third vision sensor is used to cover the right side area of ​​the lower mold wedge.

[0022] Furthermore, as a preferred embodiment, after the upper and lower templates have been used 50-100 times, the detection and compensation component detects the wear of the lower mold wedge. When the wear exceeds a first threshold, the power of the cooling system is increased by 30%-50%. When the wear exceeds a second threshold, the detection and compensation component performs coating compensation on the lower mold wedge.

[0023] Furthermore, as a preferred embodiment, the bottom of the detection compensation seat is provided with a groove, in which a forward and reverse motor is installed. The output end of the forward and reverse motor is connected to a compensation nozzle via a folding rod. The compensation nozzle is disc-shaped, and its central axis is misaligned with the central axis of the forward and reverse motor. Moreover, the projection of the compensation nozzle onto the forward and reverse motor covers the central axis of the forward and reverse motor.

[0024] Furthermore, preferably, the compensating nozzle is divided into a first region and a second region. The first region is a circular region with the projection point of the central axis of the forward and reverse motor onto the compensating nozzle as the center and the distance between the center of the compensating nozzle and the center of the first region as the radius. The second region is the region of the compensating nozzle excluding the first region. The first region is provided with a plurality of first nozzles, which are supplied with ceramic coating by a first supply pipe. The second region is provided with a plurality of second nozzles, which are supplied with transition lubricating coating by a second supply pipe.

[0025] Furthermore, as a preferred embodiment, the distribution of the second nozzles in the second region is configured such that the number of the second nozzles gradually decreases from the proximity to the first region to the distance from the first region.

[0026] Compared with the prior art, the present invention provides a wear detection device for bare sheet thermoforming molds, which has the following beneficial effects:

[0027] In this invention, in-situ online detection is achieved through integrated detection components, significantly shortening the detection time. Upon detection of wear, a compensation mechanism is immediately triggered: initially, the cooling system power is dynamically adjusted to slow down wear progression; in the middle stage, the worn area is repaired to prevent mold failure due to wear accumulation. This phased maintenance strategy effectively reduces unplanned downtime and ensures production continuity.

[0028] In this invention, the detection component, through the linkage design of the longitudinal lead screw assembly and the transverse limiting groove, covers the entire working surface of the lower mold wedge block, forming a blind-spot-free detection network. The fusion of structured light and multiple vision sensors enables micron-level surface morphology analysis, accurately locating wear areas. The compensation nozzle adopts a zoned design: the first zone is centrally sprayed with a high-hardness ceramic coating to restore the mold's geometric accuracy; the second zone is gradient-sprayed with a transitional lubricating coating to form a lubrication gradient, ensuring a smooth transition between the repaired and unworn areas. This design eliminates the need for secondary processing of the repaired surface while simultaneously improving the impact resistance and thermal stability of the repaired area. Attached Figure Description

[0029] Figure 1 This is a schematic front view of a wear detection device for bare sheet thermoforming molds.

[0030] Figure 2 This is a side view schematic diagram of a wear detection device for bare sheet thermoforming molds;

[0031] Figure 3 This is a top view schematic diagram of a wear detection device for bare sheet thermoforming molds;

[0032] Figure 4 for Figure 1 A schematic diagram of the AA cross-sectional structure;

[0033] Figure 5 A three-dimensional structural schematic diagram of a wear detection device for bare sheet thermoforming molds;

[0034] Figure 6 This is a schematic diagram of the detection and compensation component in a bare sheet thermoforming mold wear detection device;

[0035] Figure 7 This is a schematic diagram of the structure of a compensation nozzle in a wear detection device for bare sheet thermoforming molds;

[0036] In the diagram: 1. Upper template; 2. Upper mold base; 3. Cooling system; 4. Spring; 5. Limit seat; 6. Upper mold wedge; 7. Drive component; 8. Detection assembly; 9. Lower template; 10. Lower mold wedge; 11. Telescopic cylinder; 12. Lower mold base; 81. Longitudinal screw assembly; 82. Rail; 83. Slide; 84. Limit connecting plate; 85. Limit groove; 86. Screw; 87. Detection compensation assembly; 871. Detection compensation seat; 872. Limit block; 873. Detection head; 874. Compensation nozzle; 875. Folding rod; 8741. First area; 8742. First nozzle; 8743. Second area; 8744. Second nozzle; 8745. First supply pipe; 8746. Second supply pipe. Detailed Implementation

[0037] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms are interchangeable where appropriate; this is merely a way of distinguishing objects with the same attributes in the embodiments of this application. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion, so that a process, method, system, product, or apparatus that comprises a series of elements is not necessarily limited to those elements, but may include other elements not explicitly listed or inherent to those processes, methods, products, or apparatuses.

[0038] Example: In this embodiment of the invention, please refer to... Figures 1-7 A device for detecting wear of bare sheet thermoforming molds is provided, comprising:

[0039] The upper template 1 and the lower template 9 are symmetrically arranged, and a telescopic cylinder 11 is provided between the upper template 1 and the lower template 9;

[0040] The upper mold base 2 is fixed below the upper template 1. A limiting seat 5 is vertically slidably arranged in the upper mold base 2. A spring 4 is connected between the limiting seat 5 and the upper mold base 2. An upper mold wedge 6 is vertically slidably arranged in the limiting seat 5. The upper mold wedge 6 is driven by a driving component 7.

[0041] The lower mold base 12 is fixed above the lower mold plate 9. The lower mold base 12 is provided with a lower mold wedge block 10. Both the upper mold base 2 and the lower mold base 12 are provided with a cooling system 3.

[0042] The detection component 8 is disposed between the upper template 1 and the lower template 9. The detection component 8 includes at least a detection compensation component 87 that can move laterally and longitudinally. The detection compensation component 87 is used to detect the wear amount of the lower mold wedge block 10 and to perform spraying compensation based on the wear amount.

[0043] The detection and compensation component 87 detects the wear amount on the surface of the lower die wedge block 10 using non-contact sensors such as lasers, ultrasound, or contact sensors. Based on the wear amount, compensation is applied to the worn area, such as by spraying a wear-resistant coating or filling material.

[0044] The implementation includes the following steps:

[0045] During the molding stage, the telescopic cylinder 11 adjusts the distance between the upper and lower mold plates, the drive component 7 pushes the upper mold wedge block 6 down to close with the lower mold wedge block 10 to form a molding cavity, and the cooling system 3 works synchronously to control the temperature.

[0046] After molding is completed, the detection component 8 moves to the surface of the lower mold wedge 10 to detect the wear of the lower mold wedge 10 and the spraying compensation based on the wear.

[0047] It should be explained that traditional molds require machine shutdown and wedge block removal for manual inspection or inspection using equipment. This device, however, achieves in-situ online inspection through inspection component 8, significantly shortening the inspection cycle and enabling repairs in the early stages of wear. This avoids mold failure due to wear accumulation and reduces unplanned downtime. Of course, a device for inspecting the upper mold wedge block 6 can also be installed on inspection component 8; the principle is the same and will not be elaborated further.

[0048] Specifically, the detection component 8 further includes:

[0049] A longitudinal lead screw assembly 81 is disposed between the upper template 1 and the lower template 9, and has a longitudinal moving end;

[0050] A track 82 is arranged parallel to one side of the longitudinal lead screw assembly 81, and a slide block 83 is slidably arranged on it;

[0051] A limiting connecting plate 84 is connected between the longitudinal moving end and the slide 83, and a limiting groove 85 extending laterally is provided in the middle.

[0052] The detection compensation component 87 is movably disposed below the limiting groove 85.

[0053] The longitudinal lead screw assembly 81 is a common lead screw and nut pair structure, which converts rotational motion into linear motion through the nut, driving the longitudinal moving end to move longitudinally. The detection compensation assembly 87 slides laterally within the limiting groove 85, covering all detection points in the same longitudinal area, forming a full-coverage detection network.

[0054] In addition, a lead screw 86 is rotatably provided between the longitudinal moving end and the slide 83. The lead screw 86 is driven by a servo motor embedded in the slide 83, and the lead screw 86 is also connected to the detection compensation component 87.

[0055] In this embodiment, the detection compensation component 87 includes a detection compensation seat 871. A limiting block 872 is provided on the top of the compensation seat 871, and the limiting block 872 slides within a limiting groove 85. A detection head 873 is provided at each of the four corners of the bottom of the detection compensation seat 871. The four detection heads 873 are, in sequence, a first visual sensor, a second visual sensor, a third visual sensor, and a structured light emitter. The four detection heads 873 are equidistant from the center of the bottom of the detection compensation seat 871. Through the cooperation of the first visual sensor, the second visual sensor, the third visual sensor, and the structured light emitter, micron-level detection can be achieved.

[0056] In addition, the four detection heads 873 are configured such that when the detection compensation component 87 moves above the lower mold wedge block 10, the incident angle θ of the structured light emitter is 30±2° with the center normal of the lower mold wedge block 10.

[0057] The first vision sensor is used to cover the left side region of the lower mold wedge block 10;

[0058] The second vision sensor is used to cover the central area of ​​the lower mold wedge block 10;

[0059] The third vision sensor is used to cover the right side area of ​​the lower mold wedge block 10.

[0060] In other words, the bottom of the detection compensation seat 871 is square, and four detection heads 873 are installed at equal intervals at the four corners to form a symmetrical detection array.

[0061] In this process, a structured light emitter projects light strips of a specific frequency onto the surface of the lower mold wedge 10, and the deformation of the light strips is related to the surface height. The first, second, and third vision sensors respectively acquire images of the left, center, and right regions of the lower mold wedge 10, and the three-dimensional shape is reconstructed by combining the structured light data.

[0062] In addition, the optical axis of the structured light emitter is at an angle of 30±2° to the normal of the lower mold wedge block 10, thereby balancing the coverage of the light stripe and the measurement accuracy.

[0063] During implementation, after the upper template 1 and lower template 9 have worked 50-100 times, the detection and compensation component 87 detects the wear of the lower mold wedge 10. When the wear exceeds the first threshold, the power of the cooling system 3 is increased by 30%-50%. When the wear exceeds the second threshold, the detection and compensation component 87 performs spraying compensation on the lower mold wedge 10.

[0064] Among them, the first threshold (e.g., 0.1mm): if the wear exceeds the first threshold, the power of the cooling system 3 will be automatically increased to reduce the mold temperature by strengthening cooling and slowing down the wear process.

[0065] Second threshold (e.g., 0.5mm): If the wear exceeds the second threshold, the detection compensation component 87 is activated to spray compensation on the worn area.

[0066] In other words, in the early stages of wear (the first threshold), thermal stress is reduced by increasing cooling power, thus decreasing the wear rate. In the middle stages of wear (the second threshold), the worn area is directly repaired to avoid downtime caused by mold failure. This method avoids the energy waste of traditional fixed-power cooling and only repairs the worn area, reducing the amount of coating material used.

[0067] In this embodiment, the bottom of the detection compensation seat 871 is also provided with a groove, in which a forward and reverse motor is provided. The output end of the forward and reverse motor is connected to a compensation nozzle 874 through a folding rod 875. The compensation nozzle 874 is disc-shaped, and its central axis is misaligned with the central axis of the forward and reverse motor. The projection of the compensation nozzle 874 onto the forward and reverse motor covers the central axis of the forward and reverse motor.

[0068] A reversible motor drives the lever 875 to rotate, causing the compensating nozzle 874 to move in a circular motion around the axis of the motor. During this rotation, the projection of the compensating nozzle 874 always covers the area directly opposite the motor axis (i.e., the wear center area), ensuring continuous coating of this area. The circular motion of the compensating nozzle 874 coats the surrounding area, creating a transition zone with the area to be coated, preventing abrupt changes in surface height after repair. In other words, one rotation of the compensating nozzle 874 is sufficient to complete full coverage of both the area to be coated and the transition zone.

[0069] Specifically, the compensating nozzle 874 is divided into a first region 8741 and a second region 8743. The first region 8741 is a circular region with the projection point of the central axis of the forward and reverse motor onto the compensating nozzle 874 as the center and the distance between the center of the compensating nozzle 874 and the center of the first region as the radius. The second region 8743 is the region of the compensating nozzle 874 excluding the first region 8741. The first region 8741 is provided with a plurality of first nozzles 8742, which are supplied with ceramic coating by a first supply pipe 8745. The second region 8743 is provided with a plurality of second nozzles 8744, which are supplied with transition lubricating coating by a second supply pipe 8746.

[0070] Therefore, when the compensating nozzle 874 rotates, the second region 8743 forms an annular transition zone surrounding the first region 8741.

[0071] In addition, the ceramic coating components include:

[0072] Base material: water-based silicone resin or organosilicon-modified epoxy resin;

[0073] Functional fillers: nano-alumina (Al2O3) and silicon carbide (SiC) particles (40-60%) provide high hardness and wear resistance;

[0074] Anchoring reinforcement: Silane coupling agents (such as KH-560) enhance the bonding force with the metal substrate through chemical bonding;

[0075] The aforementioned transition lubricating coating includes:

[0076] Base material: High-temperature resistant silicone gel;

[0077] Lubricant: molybdenum disulfide (MoS2) or graphite (15-25%), to reduce the coefficient of friction;

[0078] Rheology control agent: Fumed silica (SiO2), which imparts thixotropic properties to the coating (high viscosity when stationary, low viscosity when sprayed).

[0079] In this embodiment, the distribution of the second nozzles 8744 in the second region 8743 is configured such that the number of the second nozzles 8744 gradually decreases from near the first region 8741 to far away from the first region 8741.

[0080] In the second region 8743, the number of second nozzles 8744 decreases from near the first region 8741 (inner edge) to far away from the first region 8741 (outer edge) (e.g., 5 nozzles / cm² at the inner edge, 2 nozzles / cm² at the outer edge), thus optimizing the spatial distribution of the coating amount. The high-density second nozzles 8744 at the inner edge form a concentrated area of ​​transitional lubricating coating, while the low-density second nozzles 8744 at the outer edge form a sparse area, creating a lubrication gradient from the repair center to the edge.

[0081] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A wear detection device for bare sheet thermoforming molds, characterized in that, include: The upper template (1) and the lower template (9) are symmetrically arranged, and a telescopic cylinder (11) is provided between the upper template (1) and the lower template (9). The upper mold base (2) is fixed below the upper template (1); The lower mold base (12) is fixed above the lower template (9). The lower mold base (12) is provided with a lower mold wedge (10) and a cooling system (3) is also provided on the lower mold base (12). The detection component (8) is disposed between the upper template (1) and the lower template (9). The detection component (8) includes at least a detection compensation component (87) capable of moving laterally and longitudinally. The detection compensation component (87) is used to detect the wear amount of the lower mold wedge (10) and the spraying compensation based on the wear amount.

2. The bare sheet thermoforming die wear detection device according to claim 1, characterized in that, The detection component (8) further includes: A longitudinal lead screw assembly (81) is disposed between the upper template (1) and the lower template (9) and has a longitudinal moving end; A track (82) is arranged parallel to one side of the longitudinal lead screw assembly (81), and a slide block (83) is slidably arranged on it. A limiting connecting plate (84) is connected between the longitudinal moving end and the slide (83), and a limiting groove (85) extending laterally is provided in the middle. The detection compensation component (87) is movably disposed below the limiting groove (85).

3. The bare sheet thermoforming die wear detection device according to claim 2, characterized in that, A lead screw (86) is rotatably provided between the longitudinal moving end and the slide (83). The lead screw (86) is driven by a servo motor embedded in the slide (83). The lead screw (86) is also connected to the detection compensation component (87) for transmission.

4. The bare sheet thermoforming die wear detection device according to claim 1, characterized in that, The detection compensation component (87) includes a detection compensation seat (871), and a detection head (873) is provided at each of the four corners of the bottom of the detection compensation seat (871). The four detection heads (873) are, in order, a first visual sensor, a second visual sensor, a third visual sensor, and a structured light emitter. The four detection heads (873) are equidistant from the bottom center of the detection compensation seat (871).

5. The bare plate thermoforming die wear detection device according to claim 4, characterized in that, The four detection heads (873) are configured such that when the detection compensation assembly (87) moves above the lower mold wedge (10), the incident angle θ of the structured light emitter is 30±2° with the center normal of the lower mold wedge (10); The first vision sensor is used to cover the left side region of the lower mold wedge (10); The second vision sensor is used to cover the central area of ​​the lower mold wedge (10); The third vision sensor is used to cover the right side area of ​​the lower mold wedge (10).

6. The bare sheet thermoforming die wear detection device according to claim 4, characterized in that, After the upper template (1) and lower template (9) have worked 50-100 times, the wear amount of the lower mold wedge (10) is detected by the detection compensation component (87). When the wear amount is greater than the first threshold, the power of the cooling system (3) is increased by 30%-50%. When the wear amount is greater than the second threshold, the lower mold wedge (10) is sprayed with compensation by the detection compensation component (87).

7. The bare sheet thermoforming die wear detection device according to claim 4, characterized in that, The bottom of the detection compensation seat (871) is also provided with a groove, in which a forward and reverse motor is provided. The output end of the forward and reverse motor is connected to a compensation nozzle (874) through a folding rod (875). The compensation nozzle (874) is disc-shaped, and its central axis is misaligned with the central axis of the forward and reverse motor. The projection of the compensation nozzle (874) onto the forward and reverse motor covers the central axis of the forward and reverse motor.

8. The bare sheet thermoforming die wear detection device according to claim 7, characterized in that, The compensating nozzle (874) is divided into a first region (8741) and a second region (8743). The first region (8741) is a circular region with the projection point of the central axis of the forward and reverse motor onto the compensating nozzle (874) as the center and the distance between the center of the compensating nozzle (874) and the center of the first region as the radius. The second region (8743) is the region of the compensating nozzle (874) excluding the first region (8741). The first region (8741) is provided with a plurality of first nozzles (8742), which are supplied with ceramic coating by a first supply pipe (8745). The second region (8743) is provided with a plurality of second nozzles (8744), which are supplied with transition lubricating coating by a second supply pipe (8746).

9. The bare sheet thermoforming die wear detection device according to claim 8, characterized in that, The distribution of the second nozzles (8744) in the second region (8743) is configured such that the number of the second nozzles (8744) gradually decreases from the area close to the first region (8741) to the area far away from the first region (8741).

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