Apparatus for preparing a micro-test sample

Abstract

The application discloses a kind of equipment for preparing micro detection sample, belong to material sample preparation technical field, solve the existing artificial preparation micro detection sample with the problems of operation complicated, sample is easily contaminated and security hidden trouble is prominent etc..The equipment takes the equipment body with sealed sample preparation chamber as carrier, chamber is integrated electromagnetic induction heating device, automatic turnover mechanism, forming cooling system and automatic weighing system, and the metal sample is melted by electromagnetic induction heating mode, and the sample melting container is turned over by automatic turnover mechanism, and the molten sample is poured into the lower forming crucible;Forming crucible outside is equipped with circulating water-cooled cladding cooling jacket, and the sample is rapidly cooled and formed;Automatic weighing system is arranged at the bottom of forming crucible, and the weight of sample is detected in real time, and when the weight reaches the preset threshold, the output signal is output, the turnover mechanism is driven to reset and stop pouring, and the weight closed-loop control is formed.

Description

Technical Field

[0001] This invention relates to the field of material sample preparation technology, and more specifically, to an apparatus for preparing miniature detection samples. Background Technology

[0002] In the field of quality control of metallic materials, the combustion method is the mainstream method for detecting the content of trace elements such as carbon, oxygen, and hydrogen, and is widely used in the composition verification of high-end metallic materials such as bearing steel and special alloys. This testing method has stringent requirements for the sample. Industry standards clearly stipulate that the weight of the test sample must be controlled within the range of 0.5-1.0g, which is a typical micro sample. At the same time, the purity of the sample composition, the consistency of weight, and the regularity of morphology directly affect the completeness of combustion and the accuracy of the test results, and are the core prerequisites for ensuring the accuracy of the test.

[0003] Currently, the industry generally uses a manual sample preparation process for the preparation of such miniature test samples: operators use sandpaper to grind and scrape the metal base material to obtain metal fragments or small pieces of sample, and then repeatedly weigh, add or remove samples using a balance until the weight meets the testing requirements. This process has been used for many years, but it has many unresolved defects in practical applications.

[0004] First, the operation process is cumbersome and the sample preparation efficiency is low. The process of manual grinding and repeated weighing and adjustment relies on manual operation, and the preparation of a single qualified sample takes a long time. When facing the demand for batch testing, the labor cost is high and the production capacity is insufficient, making it difficult to keep up with the pace of efficient testing.

[0005] Secondly, there are significant safety hazards during operation. During the grinding and cutting process, operators' hands come into direct contact with sandpaper and metal edges, making them highly susceptible to scratches or abrasions caused by sandpaper friction and metal burrs. Long-term repetitive work can easily lead to occupational injuries, which does not meet the requirements for safe production control.

[0006] Third, the risk of sample contamination is high, limiting detection accuracy. During manual operation, hand secretions and environmental dust can easily adhere to the sample surface, and sandpaper fragments may also mix into the sample, causing contamination of the sample components. Practical application data shows that the carbon content detection error caused by manual sample preparation can reach more than ±0.005%, which cannot meet the high-precision detection requirements of high-end metal materials.

[0007] Fourth, insufficient weight control precision leads to a high rework rate. The sampling amount relies entirely on the operator's experience and judgment, resulting in a persistently high rate of sample weight deviations. This often necessitates multiple rework adjustments, further reducing sample preparation efficiency. Moreover, the inconsistent sample weights prepared by different operators reduce the comparability and stability of test results.

[0008] In summary, existing methods for preparing micro-samples suffer from a series of problems, including cumbersome operation, low efficiency, significant safety hazards, high risk of contamination, and insufficient precision in weight and morphology control. These methods are no longer adequate for the high-precision composition detection needs of advanced metallic materials. Currently, there is no automated dedicated preparation equipment for this scenario in the industry. Therefore, there is an urgent need to develop a device that can achieve automated, high-precision, and contamination-free sample preparation to address the many pain points of existing processes. Summary of the Invention

[0009] To address the shortcomings of existing technologies, the present invention aims to provide a device for preparing micro-detection samples. Through an integrated design that combines electromagnetic induction heating in a vacuum environment, automatic flipping casting, closed-loop weighing control, and rapid cooling molding, the device achieves automated and high-precision preparation of micro-detection samples, replacing the traditional manual grinding and cutting process and improving the safety, accuracy, and efficiency of sample preparation.

[0010] To achieve the above objectives, the present invention provides the following technical solution: a device for preparing micro-test samples, comprising a device body, wherein a sample preparation chamber is provided inside the device body; the sample preparation chamber is provided with an electromagnetic induction heating device, an automatic flipping mechanism, a forming cooling system, and an automatic weighing system; the electromagnetic induction heating device is used to electromagnetically induction heat and melt the test sample; the automatic flipping mechanism is used to carry the sample melting container and, after the sample melts, drives the sample melting container to flip, pouring the molten sample into the forming cooling system; the forming cooling system is used to receive the molten sample and cool and shape the micro-sample, including a forming crucible and a cooling sleeve fitted outside the forming crucible, wherein the cooling sleeve uses circulating water cooling to rapidly cool the sample; the automatic weighing system is located below the forming crucible, and its signal output terminal is connected to a control unit, forming a control closed loop with the automatic flipping mechanism through the control unit, for real-time detection of the sample weight in the forming crucible, and when the sample weight reaches a preset threshold, outputting a control signal to drive the automatic flipping mechanism to reset and stop pouring; The device body is provided with a vacuum exhaust port that is connected to the sample preparation chamber for extracting air from the chamber to create a vacuum environment. The device body is also provided with a control unit, which is electrically connected to the electromagnetic induction heating device, the automatic flipping mechanism, and the automatic weighing system, respectively, for regulating the coordinated operation of each module.

[0011] The present invention is further configured such that: the electromagnetic induction heating device includes a heating coil and a sample melting container, the heating coil is arranged around the outside of the sample melting container, the heating coil is electrically connected to the control unit, the heating power is adjusted by the control unit, and the control unit has a built-in temperature preset module, a heating time setting module, a flip parameter adjustment module and a weight threshold module.

[0012] The present invention is further configured such that: the automatic flipping mechanism includes a drive motor and a flipping bracket; the drive motor is electrically connected to the control unit; a transmission device is provided between the drive motor and the flipping bracket; the sample melting container is disposed on the flipping bracket; and the drive motor drives the transmission device to rotate, thereby causing the flipping bracket to flip synchronously.

[0013] The present invention is further configured such that: the transmission device includes a driving gear, a driven gear, and a tilting table; the driving gear is fixedly mounted on the output shaft of the drive motor; the driven gear is fixedly mounted on the tilting table; the tilting bracket is fixedly mounted on the tilting table; and the driving gear and the driven gear mesh with each other; when the drive motor outputs power, the tilting table drives the tilting bracket to tilt through the meshing transmission of the driving gear and the driven gear.

[0014] The present invention is further configured such that: a water-cooling channel is provided inside the cooling jacket, the water-cooling channel being used to communicate with an external water-cooling circulation system; and the forming crucible is fitted and snapped into the cooling jacket.

[0015] The present invention is further configured such that: the automatic weighing system includes a weight sensor, which is supported at the bottom of the cooling jacket and supports the entire molding cooling system to detect the weight of the sample in the molding crucible in real time; the signal output terminal of the weight sensor is connected to the control unit, and the control unit controls the start, stop and reset of the automatic flipping mechanism according to the weight signal.

[0016] The present invention is further configured to include a temperature measurement and display unit, which includes a thermocouple probe and a display screen. The thermocouple probe extends into the sample preparation chamber and is attached to the temperature measurement point of the sample melting container. The display screen is embedded in the outer wall of the device body. The thermocouple probe is electrically connected to the control unit and is used to feed back temperature data to the control unit. The display screen is used to display the temperature value, over-temperature warning and temperature curve in real time.

[0017] The invention is further configured such that: an observation window is provided on the device body corresponding to the sample preparation chamber; the observation window is made of tempered glass; a sealing gasket is provided between the observation window and the device body; and the edges are fixed by a high-temperature resistant sealing strip; the vacuum exhaust port is connected to a vacuum pumping pipeline; and a one-way valve is provided on the pipeline to prevent gas backflow; the vacuum exhaust port is adapted to a vacuum pump interface, which can achieve an adjustable chamber gauge pressure vacuum of 0~-0.1MPa.

[0018] The present invention is further configured such that: an emergency stop button is installed on the outer side wall of the device body, the emergency stop button is electrically connected to the control unit, and when the emergency stop button is triggered, the control unit immediately cuts off the power supply to the electromagnetic induction heating device and the automatic flipping mechanism.

[0019] The present invention is further configured such that: a support foot is provided at the bottom of the device body, the support foot is made of anti-slip rubber material, and the support foot has a built-in shock-absorbing pad.

[0020] By adopting the above technical solution, the following technical effects are achieved: 1. High degree of automation and significantly improved sample preparation efficiency: The entire process of heating, turning, weighing and cooling is integrated into automated control, and a single sample preparation can be completed in a short time. Compared with manual sample preparation, the efficiency is improved and the labor cost is greatly reduced.

[0021] 2. High weight control accuracy: The automatic stop of the sample is achieved by using closed-loop weight control, and the weight accuracy of the sample is far superior to that of manual sample preparation, ensuring the stability and comparability of the test results.

[0022] 3. Pollution-free preparation and more accurate test results: The entire process is completed in a vacuum-sealed chamber without human contact, avoiding problems such as human hand contamination and sandpaper debris mixing in. This can reduce the error in carbon content detection and meet the high-precision testing needs of high-end materials.

[0023] 4. Safe operation and elimination of occupational injury risks: The entire process is automated, and operators do not need to come into contact with high-temperature samples and molds, which fundamentally avoids occupational injuries such as scratches and burns, and meets the requirements for safe production. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a partial structural diagram of the present invention; Figure 3 This is a partial working state of the present invention. Figure 1 ; Figure 4 This is a partial working state of the present invention. Figure 2 ; Figure 5 This is a partial working state of the present invention. Figure 3 ; Figure 6 This is a bottom view of the structure of the present invention.

[0025] 1. Equipment body; 2. Sample preparation chamber; 3. Electromagnetic induction heating device; 31. Heating coil; 32. Sample melting container; 4. Automatic flipping mechanism; 41. Drive motor; 42. Flipping bracket; 43. Drive gear; 44. Driven gear; 45. Flipping table; 5. Molding cooling system; 51. Molding crucible; 52. Cooling jacket; 53. Water cooling channel; 6. Automatic weighing system; 61. Weight sensor; 9. Temperature display unit; 91. Thermocouple probe; 92. Display screen; 10. Observation window; 11. Emergency stop button; 12. Support feet. Detailed Implementation

[0026] Reference Figures 1 to 6 The embodiments of the present invention will be further described below.

[0027] This embodiment discloses a device for preparing miniature detection samples, including a device body 1, which is a box-type structure with a sealed sample preparation chamber 2 inside. The sample preparation chamber 2 is a vacuum-sealed cavity that can be opened and closed through a sealed door, used for placing samples and completing the entire preparation process. The sample preparation chamber 2 integrates an electromagnetic induction heating device 3, an automatic flipping mechanism 4, a molding cooling system 5, and an automatic weighing system 6.

[0028] The electromagnetic induction heating device 3 includes a heating coil 31 and a sample melting container 32. The heating coil 31 is spirally arranged around the outside of the sample melting container 32. The heating coil 31 is electrically connected to the control unit on the device body 1, and the control unit outputs a high-frequency current to achieve electromagnetic induction heating. The sample melting container 32 is used to hold the metal base material sample to be melted.

[0029] The automatic tilting mechanism 4 includes a drive motor 41, a tilting bracket 42, a driving gear 43, and a driven gear 44. The drive motor 41 is fixedly mounted on the bottom wall of the sample preparation chamber 2, and the driving gear 43 is coaxially fixedly mounted on the end of the output shaft of the drive motor 41. The driving gear 43 and the driven gear 44 mesh with each other. The sample melting container 32 is fixedly mounted inside the tilting bracket 42 and rotates synchronously with the tilting bracket 42. The drive motor 41 is a servo motor, which can precisely control the rotation angle and speed to ensure a smooth tilting and pouring process.

[0030] The molding cooling system 5 is located below the automatic tilting mechanism 4 in a tilting position, and includes a molding crucible 51 and a cooling jacket 52. A water-cooling channel 53 is provided inside the cooling jacket, and the inlet and outlet of the water-cooling channel 53 extend out of the equipment body 1 through pipes, connecting to an external water-cooling circulation system. The molding crucible 51 is miniaturized, with a volume suitable for preparing samples of 0.5-1.0g. The molding crucible 51 is snapped into the internal groove of the cooling jacket 52, allowing for quick removal and replacement.

[0031] The automatic weighing system 6 includes a high-precision weight sensor 61, which is located at the bottom of the cooling jacket 52 and supports the weight of the entire molding and cooling system 5. The signal output of the weight sensor 61 is connected to the control unit to collect the sample weight data in the molding crucible 51 in real time. When the weight reaches a preset threshold, the control unit sends a reverse command to the drive motor 41, which drives the flipping bracket 42 to reset, stops the material pouring, and realizes closed-loop weight control.

[0032] The top of the main body 1 is equipped with a vacuum exhaust port, which is connected to the sample preparation chamber 2. An external vacuum extraction pipeline is connected to the pipeline, and a one-way valve is installed on the pipeline to prevent gas backflow when the machine is stopped. With an external vacuum pump, the chamber's gauge pressure can be continuously adjusted from 0 to -0.1 MPa to meet the vacuum heating requirements of different metallic materials.

[0033] The device body 1 is also equipped with a temperature measurement and display unit 9, including a thermocouple probe 91 and a display screen 92. The thermocouple probe 91 extends from the side wall of the chamber, with its end attached to the temperature measurement point on the outer wall of the sample melting container 32, collecting temperature data in real time and transmitting it to the control unit. The display screen 92 is embedded in the front outer wall of the device body 1, and can display parameters such as the current chamber temperature, heating time, and sample weight in real time, supporting over-temperature warning and temperature curve traceability display.

[0034] An observation window 10 is provided on the front of the equipment body 1, corresponding to the sample preparation chamber 2. The observation window 10 is made of high-temperature resistant tempered glass, and is fixed around the perimeter by high-temperature resistant sealing strips and sealing gaskets to ensure the airtightness of the chamber. Operators can directly observe the melting and casting state of the sample inside through the observation window 10.

[0035] An emergency stop button 11 is installed on the outer wall of the equipment body 1. The emergency stop button 11 is connected to the control circuit of the control unit. When triggered, it can immediately cut off the power supply to the heating and flipping mechanism to achieve emergency stop. Support feet 12 are provided at the four corners of the bottom of the equipment body 1. The support feet 12 are made of non-slip rubber and have embedded shock-absorbing pads inside, which can reduce the impact of equipment operation vibration on the balance accuracy.

[0036] The control unit is located in the electrical control compartment of the equipment body 1 and is electrically connected to the electromagnetic induction heating device 3, drive motor 41, weight sensor 61, thermocouple probe 91, and emergency stop button 11. The control unit has multiple built-in functional modules for temperature preset, heating time setting, flip parameter adjustment, and weight threshold. It can store multiple sets of process parameters and realize one-button start-up of fully automated preparation.

[0037] The following example, using the preparation of micro-test samples of bearing steel, illustrates the specific working process of this equipment: Sample loading and vacuuming stage: Open the chamber sealing door, place a bearing steel slice weighing approximately 1g into the sample melting container 32, and close the sealing door. Start the external vacuum pump and evacuate the chamber to -0.01MPa through the vacuum exhaust port to prevent oxidation and decarburization during sample heating.

[0038] Heating and melting stage: The electromagnetic induction heating device 3 is activated by preset heating temperature of 1400℃ and heating time of 2 minutes by the control unit. Thermocouple probe 91 monitors the temperature in real time, and the control unit automatically adjusts the heating power according to the temperature feedback to maintain temperature stability and completely melt the sample into a liquid state.

[0039] In the flipping casting and weighing stage: After the heating time is reached, the control unit starts the drive motor 41, which, through the meshing transmission of the driving gear 43 and the driven gear 44, drives the flipping bracket 42 to slowly flip, pouring the molten metal in the sample melting container 32 into the forming crucible 51 below. The weight sensor 61 monitors the weight of the sample in the forming crucible 51 in real time. When the weight reaches the preset value of 0.7g, the control unit immediately controls the drive motor 41 to reverse, driving the flipping bracket 42 to reset and stop pouring.

[0040] Cooling and molding stage: Start the external water cooling circulation system. Cooling water circulates through the water cooling channel 53 inside the cooling jacket 52 to rapidly cool the sample in the molding crucible 51. The cooling time is 1 minute, so that the sample can be completely solidified and molded.

[0041] Sample removal stage: After cooling, air is introduced into the sample preparation chamber 2 to break the vacuum, the sealing door is opened, and the forming crucible 51 is taken out to obtain a miniature bearing steel test sample with accurate weight and regular shape, thus completing one sample preparation process.

[0042] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An apparatus for preparing miniature detection samples, characterized in that, The device includes a main body with a sample preparation chamber inside. The sample preparation chamber contains an electromagnetic induction heating device, an automatic tilting mechanism, a molding and cooling system, and an automatic weighing system. The electromagnetic induction heating device melts the sample using electromagnetic induction heating. The automatic tilting mechanism carries the sample melting container and tilts it after melting, pouring the molten sample into the molding and cooling system. The molding and cooling system receives the molten sample and cools and shapes the micro-sample, including a molding crucible and a cooling sleeve covering the outside of the molding crucible. The cooling sleeve uses circulating water cooling to rapidly cool the sample. The automatic weighing system is located below the molding crucible, and its signal output is connected to a control unit. The control unit and the automatic tilting mechanism form a control closed loop to monitor the sample weight in the molding crucible in real time. When the sample weight reaches a preset threshold, a control signal is output to drive the automatic tilting mechanism to reset and stop pouring. The main body has a vacuum exhaust port connected to the sample preparation chamber to extract air from the chamber and create a vacuum environment. The device body is also equipped with a control unit, which is electrically connected to the electromagnetic induction heating device, the automatic flipping mechanism, and the automatic weighing system, respectively, and is used to regulate the coordinated operation of each module.

2. The apparatus for preparing micro-detection samples according to claim 1, characterized in that, The electromagnetic induction heating device includes a heating coil and a sample melting container. The heating coil is arranged around the outside of the sample melting container. The heating coil is electrically connected to the control unit, and the heating power is adjusted by the control unit. The control unit has a built-in temperature preset module, a heating time setting module, a flip parameter adjustment module, and a weight threshold module.

3. The apparatus for preparing micro-detection samples according to claim 2, characterized in that, The automatic flipping mechanism includes a drive motor and a flipping bracket. The drive motor is electrically connected to the control unit. A transmission device is provided between the drive motor and the flipping bracket. The sample melting container is placed on the flipping bracket. The drive motor drives the transmission device to rotate and drive the flipping bracket to flip synchronously.

4. The apparatus for preparing micro-detection samples according to claim 3, characterized in that, The transmission device includes a driving gear, a driven gear, and a tilting table. The driving gear is fixedly mounted on the output shaft of the drive motor, the driven gear is fixedly mounted on the tilting table, and the tilting bracket is fixed on the tilting table. The driving gear and the driven gear mesh with each other. When the drive motor outputs power, the tilting table drives the tilting bracket to tilt through the meshing transmission of the driving gear and the driven gear.

5. The apparatus for preparing micro-detection samples according to claim 1, characterized in that, The cooling jacket has a water-cooling channel inside, which is used to connect with an external water-cooling circulation system; the molding crucible is fitted and snapped into the cooling jacket.

6. The apparatus for preparing miniature detection samples according to claim 1, characterized in that, The automatic weighing system includes a weight sensor, which is supported at the bottom of the cooling jacket and supports the entire molding cooling system to detect the weight of the sample in the molding crucible in real time. The signal output terminal of the weight sensor is connected to the control unit, which controls the start, stop and reset of the automatic flipping mechanism according to the weight signal.

7. The apparatus for preparing miniature detection samples according to claim 1, characterized in that, It also includes a temperature measurement and display unit, which includes a thermocouple probe and a display screen. The thermocouple probe extends into the sample preparation chamber and is attached to the temperature measurement point of the sample melting container. The display screen is embedded in the outer wall of the device body. The thermocouple probe is electrically connected to the control unit and is used to feed back temperature data to the control unit. The display screen is used to display the temperature value, over-temperature warning and temperature curve in real time.

8. The apparatus for preparing micro-detection samples according to claim 1, characterized in that, The device body has an observation window at the position corresponding to the sample preparation chamber. The observation window is made of tempered glass and a sealing gasket is provided between the observation window and the device body. The edges are fixed by high-temperature resistant sealing strips. The vacuum exhaust port is connected to a vacuum pumping pipeline, and a one-way valve is provided on the pipeline to prevent gas backflow. The vacuum exhaust port is adapted to a vacuum pump interface.

9. The apparatus for preparing micro-detection samples according to claim 1, characterized in that, An emergency stop button is installed on the outer wall of the device body. The emergency stop button is electrically connected to the control unit. When the emergency stop button is triggered, the control unit immediately cuts off the power supply to the electromagnetic induction heating device and the automatic flipping mechanism.

10. The apparatus for preparing miniature detection samples according to claim 1, characterized in that, The bottom of the device body is equipped with support feet, which are made of non-slip rubber and have built-in shock-absorbing pads.

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