X-ray on-line thickness measuring device

Abstract

The utility model relates to an X-ray on-line thickness measuring device, which mainly solves the problems that the thickness of soft materials such as sponge, composite leather, composite sponge and the like is difficult to detect and the precision is poor in on-line measurement in the prior art. According to the technical scheme, the novel X-ray online thickness measuring device comprises an X-ray emitting machine (1), an X-ray receiving machine (2), a feeding guide roller (3-1), a discharging guide roller (3-2), a feeding reference roller (4-1), a discharging reference roller (4-2), a linkage shaft (5), a connecting rod (6), a control panel (8), a case frame (9), a mechanism presser foot (10) and a test base material (12), and the problem is well solved. The method can be applied to the industries of sponge, composite leather and composite sponge.

Description

Technical Field

[0001] This utility model relates to an online X-ray thickness measurement device. Background Technology

[0002] Modern consumers have increasingly higher expectations for the quality of automotive interiors, focusing not only on aesthetics and comfort but also on environmental friendliness, durability, and safety. To meet these demands, OEMs are imposing more stringent standards on the processing of composite materials for automotive interiors. This includes strict control over the surface quality, dimensional accuracy, and physical properties of the materials. Traditional processing techniques for automotive interior composite materials have many limitations and are no longer sufficient to meet the evolving needs of customers, necessitating the introduction of more competitive new processes and equipment.

[0003] An X-ray thickness gauge is a thickness measurement device based on the principle of X-ray penetration. When X-rays pass through a material, their intensity decreases due to absorption and scattering by the material. The greater the thickness of the material, the stronger the absorption of X-rays, and the lower the intensity of the transmitted X-rays. Therefore, by measuring the intensity of the transmitted X-rays, the thickness of the material can be calculated. Thus, online thickness measurement equipment using X-rays, combined with conversion formulas for various materials, can measure the thickness of multiple materials. Because it measures the attenuation of X-rays after penetration, the X-rays are unaffected by the surface condition of the material, resulting in high accuracy and repeatability. Specifically, the accuracy is below 0.0001 mm, and the repeatability is below 0.001 mm. In actual production, an online X-ray thickness gauge consists of an upper X-ray source platform, a lower X-ray receiving source platform, a motor, a transmission roller device, a signal processing device, and a control panel. When used in conjunction with an automated production line, it can perform online thickness measurement of materials such as sponge, composite leather, and composite sponge.

[0004] Chinese patent CN212620595U discloses an automatic thickness detection device. This invention mainly solves the technical problems of large errors in manual measurement of product thickness, untimely product inspection leading to increased defective products and missed inspections, and the inability to effectively trace and analyze thickness problems in existing technologies. It provides a new automatic thickness detection device. By adopting a technical solution including a base 1, guide roller 2, reference roller 3, substrate 4, motor 5, data transmission line 6, and main unit 7, this technical problem is effectively solved and can be used in the industrial production of automotive composite materials. However, the triangular displacement laser sensor, in principle, uses a laser receiver to receive the reflected laser light emitted by a laser emitter from the surface of the object being measured, and calculates the actual displacement to obtain geometric data. Due to the linear propagation of laser light, the surface flatness and smoothness of the object being measured are highly demanding. Most automotive composite materials are soft materials with relatively uneven surfaces, such as the fuzz of non-woven fabrics and the pores of sponges. Furthermore, triangular displacement laser sensors utilize the principles of light reflection and geometry, requiring a high degree of stability from the mechanism. While they perform well in static environments such as laboratories, in online production, vibrations and movement of the mechanism and products often lead to significant deviations in measurement results. Therefore, it is evident that laser online thickness measurement devices have a narrow application range and large repeatability deviations. Specifically, while accuracy is below 0.005mm, repeatability is above 0.08mm, significantly limiting their practical application in manufacturing. Summary of the Invention

[0005] The technical problem this invention aims to solve is the difficulty and low accuracy of online thickness measurement for soft materials such as composite leather, sponge, and composite sponge. It provides a new X-ray online thickness measurement device that offers advantages such as ease of testing sponge, composite leather, and composite sponge, as well as high testing accuracy.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: An online X-ray thickness measurement device, comprising: an X-ray emitting machine 1, an X-ray receiving machine 2, a feeding guide roller 3-1, a discharging guide roller 3-2, a feeding reference roller 4-1, a discharging reference roller 4-2, a linkage shaft 5, a connecting rod 6, a control panel 8, a chassis frame 9, a mechanism pressure foot 10, and a test substrate 12, wherein the X-ray emitting machine 1 includes a first drag chain 1-1, a first slide rail 1-2, a first fixing rod 1-3, and a first lead screw. 1-4, X-ray sensor 1-5; The X-ray receiving machine 2 includes a second drag chain 2-1, a second slide rail 2-2, a second fixing rod 2-3, a second lead screw 2-4, and an X-ray receiver 2-5; The X-ray emitting machine 1 and the X-ray receiving machine 2 are both fixed on the chassis frame 9. The X-ray emitting machine 1 is integrated into the upper frame of the chassis frame 9, and the X-ray receiving machine 2 is integrated into the lower frame of the chassis frame 9. The positions of the two are kept consistent in real time by an integrated control system. The feed guide roller 3-1 and discharge guide roller 3-2 are installed in the upper grooves of the left and right frames for feeding and discharging materials; the feed reference roller 4-1 and discharge reference roller 4-2 are installed in the lower grooves of the left and right frames; the linkage shaft 5 is located between the groove and the connecting rod 6, and is responsible for transmitting the torque of the motor built into the chassis frame 9 to the connecting rod 6 to drive the feed guide roller 3-1, discharge guide roller 3-2, feed reference roller 4-1, and discharge reference roller 4-2; the control panel 8 is connected to the built-in host via a wiring harness for manual interaction and... Data supervision; the test substrate 12 passes on the feed guide roller 3-1, the discharge guide roller 3-2, the feed reference roller 4-1, and the discharge reference roller 4-2 in the direction shown by the lines; characterized in that the mechanism pressure foot 10 is fixed to the whole machine or the fixing mechanism by bolts and nuts, and is made of marble; the feed guide roller 3-1 and the discharge guide roller 3-2 are arranged horizontally and parallel; the feed reference roller 4-1 and the discharge reference roller 4-2 are arranged horizontally and parallel; and the weight of the feed reference roller 4-1 and the discharge reference roller 4-2 is consistent.

[0007] In the above technical solution, preferably, the first slide rail 1-2 and the first lead screw 1-4 are both fixed inside the chassis frame 9, the upper inner end of the first fixed rod 1-3 is fixedly connected to the other end of the first drag chain 1-1, and the first drag chain 1-1 carries the X-ray sensor 1-5 in a reciprocating motion set by the host program on the first fixed rod 1-3 under the drive of the motor; the second slide rail 2-2 and the second lead screw 2-4 are both fixed inside the chassis frame 9, the upper inner end of the second fixed rod 2-3 is fixedly connected to the other end of the second drag chain 2-1, and the second drag chain 2-1 carries the X-ray receiver 2-5 in a reciprocating motion set by the host program on the second fixed rod 2-3 under the drive of the motor.

[0008] In the above technical solution, preferably, the irregular vibration of the feed is controlled by the feed reference roller 4-1 and the discharge reference roller 4-2. The feed guide roller 3-1 and the discharge guide roller 3-2 adjust the tension and stability of the feed according to the feed speed. A tension controller is placed inside the machine box between the two guide rollers. After receiving the signal from the force sensor, it will adjust the tension in real time to change the incoming state of the detected material. The rollers have been dynamically balanced and are made of steel to reduce the deformation of the material. The surface is electroplated to ensure flatness and uniform friction. The main measuring structure of the machine is made of marble to reduce the vibration of the feed.

[0009] In the above technical solution, preferably, the sensing head of the X-ray emitting machine 1 uses a 30 KeV X-ray emitter and a gas ionization chamber / solid ionization detector. Such a sensing head can generate high-intensity X-ray particles that can penetrate thicker materials, and the sampling distance can exceed 11 mm. Using a high-speed linear motor, the line scanning speed can reach 60 m / min, the sampling frequency is 200 kHz, the spot coverage is 3.2*38 mm, and the overall thickness gauge frame width is 2.2 m.

[0010] In the above technical solution, preferably, the online thickness measuring device further includes an alarm 7 and a dust removal pipe 11; the alarm 7 is connected to the built-in host through a wiring harness and is used to issue an alarm for products that exceed specifications; the dust removal pipe 11 is fixed to the right frame by bolts and nuts.

[0011] In the above technical solution, preferably, the fixing mechanism includes a first slide rail 1-2, a first fixing rod 1-3, a second slide rail 2-2, a second fixing rod 2-3, a mechanism pressure foot 10, an overall base of the machine base, a side slide rail, a support frame, and an internal support structure for the motor.

[0012] This invention employs X-ray transmission method for non-contact measurement. After the X-ray beam generated by the X-ray emitting machine 1 penetrates the test substrate 12, the X-ray receiving machine 2 calculates the thickness value in real time through particle number loss detection. The control system ensures measurement accuracy through the following technologies:

[0013] 1. Dynamic compensation system: The slide rail-screw mechanism enables synchronous positioning of the transmitting / receiving units;

[0014] 2. Vibration suppression design: The feed reference roller 4-1 and the discharge reference roller 4-2 are equipped with a buffer structure to ensure that the amplitude is ≤0.05mm under high-speed conditions;

[0015] 3. Environmental optimization: The dust removal pipe 11 maintains the cleanliness of the measurement area, and the mechanism pressure foot 10 is fixed by bolts and nuts to balance or fix the entire machine. The marble material of the mechanism provides the mechanical stability of ±0.1mm.

[0016] This invention achieves compatibility between 0.01mm-level measurement accuracy and 120m / min linear speed through mechatronics design, improving efficiency by more than 300% compared to traditional contact thickness measuring devices. Furthermore, during the production process, data is accumulated and analyzed through a cloud platform, and calibrated and corrected with laboratory test data to further correct data deviations and obtain accurate measurement data. Attached Figure Description

[0017] Appendix Figure 1 This is a schematic diagram of an online X-ray thickness measurement device;

[0018] Appendix Figure 2 This is a structural diagram of an X-ray emitting machine;

[0019] Appendix Figure 3 This is a structural diagram of an X-ray receiving machine;

[0020] Appendix Figure 4 This is a side view of the X-ray online thickness measurement device;

[0021] Appendix Figure 5 , 6 7 are charts showing the results of tests on different products using this utility model, laser, and measured values.

[0022] Among them, 1 is an X-ray emitting machine, 2 is an X-ray receiving machine, 3-1 is a feeding guide roller, 3-2 is a discharging guide roller, 4-1 is a feeding reference roller, 4-2 is a discharging reference roller, 5 is a linkage shaft, 6 is a connecting rod, 7 is an alarm, 8 is a control panel, 9 is a chassis frame, 10 is a mechanism pressure foot, 11 is a dust removal pipe, 12 is a test substrate, 1-1 is a first drag chain, 1-2 is a first slide rail, 1-3 is a first fixing rod, 1-4 is a first lead screw, 1-5 is an X-ray sensor; 2-1 is a second drag chain, 2-2 is a second slide rail, 2-3 is a second fixing rod, 2-4 is a second lead screw, and 2-5 is an X-ray receiver. Detailed Implementation

[0023]

Example 1

[0024] An online X-ray thickness measurement device includes: an X-ray emitting machine 1, an X-ray receiving machine 2, an infeed guide roller 3-1, an outfeed guide roller 3-2, an infeed reference roller 4-1, an outfeed reference roller 4-2, a linkage shaft 5, a connecting rod 6, a control panel 8, a chassis frame 9, a mechanism pressure foot 10, and a test substrate 12. The X-ray emitting machine 1 includes a first drag chain 1-1, a first slide rail 1-2, a first fixing rod 1-3, a first lead screw 1-4, and an X-ray sensor 1-5. The X-ray receiving machine 2 includes a second drag chain 2-1, a second slide rail 2-2, a second fixing rod 2-3, a second lead screw 2-4, and an X-ray receiver 2-5. Both the X-ray emitting machine 1 and the X-ray receiving machine 2 are fixed to the chassis frame 9. The X-ray emitting machine 1 is integrated into the upper frame of the chassis frame 9, and the X-ray receiving machine 2 is integrated into the lower frame of the chassis frame 9. Their positions are kept consistent in real time by an integrated control system. The infeed guide roller 3-1, the outfeed guide roller 3-2, the infeed reference roller 4-1, the outfeed reference roller 4-2, a linkage shaft 5, a connecting rod 6, a control panel 8, a chassis frame 9, a mechanism pressure foot 10, and a test substrate 12. Guide rollers 3-2 are installed in the upper grooves of the left and right frames for feeding and discharging materials; the feed reference rollers 4-1 and 4-2 are installed in the lower grooves of the left and right frames; the linkage shaft 5 is located between the grooves and the connecting rod 6, and is responsible for transmitting the torque of the motor built into the chassis frame 9 to the connecting rod 6 to drive the feed guide rollers 3-1, 3-2, feed reference rollers 4-1, and 4-2; the control panel 8 is connected to the built-in host via a wiring harness for manual interaction and data monitoring; testing. The substrate 12 travels along the feed guide roller 3-1, the discharge guide roller 3-2, the feed reference roller 4-1, and the discharge reference roller 4-2 in the direction shown by the lines; characterized in that the mechanism presser foot 10 is made of marble and is used to fix the entire machine or the fixing mechanism by bolts and nuts; the feed guide roller 3-1 and the discharge guide roller 3-2 are arranged horizontally and parallel; the feed reference roller 4-1 and the discharge reference roller 4-2 are arranged horizontally and parallel; and the weight of the feed reference roller 4-1 and the discharge reference roller 4-2 is consistent.

[0025] The first slide rail 1-2 and the first lead screw 1-4 are both fixed inside the chassis frame 9. The upper inner end of the first fixed rod 1-3 is fixedly connected to the other end of the first drag chain 1-1. The first drag chain 1-1 carries the X-ray sensor 1-5 and performs a reciprocating motion set by the host program on the first fixed rod 1-3 under the drive of the motor. The second slide rail 2-2 and the second lead screw 2-4 are both fixed inside the chassis frame 9. The upper inner end of the second fixed rod 2-3 is fixedly connected to the other end of the second drag chain 2-1. The second drag chain 2-1 carries the X-ray receiver 2-5 and performs a reciprocating motion set by the host program on the second fixed rod 2-3 under the drive of the motor.

[0026] The X-ray emitting machine 1 uses a 30 KeV X-ray emitter and a gas ionization chamber / solid ionization detector in its sensing head. This sensing head can generate high-intensity X-ray particles that can penetrate thicker materials and has a sampling distance of more than 11 mm. It uses a high-speed linear motor, with a line scan speed of 60 m / min, a sampling frequency of 200 kHz, a spot coverage of 3.2*38 mm, and an overall thickness gauge frame width of 2.2 m.

[0027] Step 1: Start the system, run the online X-ray thickness gauge, and calibrate the required thickness range of the foam material;

[0028] Step 2: Take a sample of the foam material and test its thickness using the corresponding industry testing standard. Input the sample into the online thickness gauge's operating platform library for further processing.

[0029] The curve points corresponding to the particle loss rate after X-rays penetrate an object. Foam material is a new material with relatively uniform density, so the initial curve is a straight line with equal proportions. Subsequent measurement data will form a database, which will be further filled with the specific particle loss rate for each thickness to form a more accurate curve. The corresponding thickness can be directly obtained from the curve points. For new materials with uniform thickness, experiments have shown that the intensity attenuation of X-rays after penetrating the material is proportional to the distance the ray travels in the material. The intensity of the incident ray is I0. When it enters a uniformly dense absorber, its intensity at point x is Ix. When it passes through a thickness dx, the intensity attenuation is dI. Define μ as the ratio of X-rays absorbed when passing through a unit thickness, then we have: -dI=μ·Ix·dx. Considering the boundary conditions and integrating, we get: Ix=I0 e-μx, where μ is called the linear attenuation coefficient and x is the sample thickness.

[0030] Step 3: The foam material is moved online and conveyed to the feed guide roller 3-1, the discharge guide roller 3-2, the feed reference roller 4-1, and the discharge reference roller 4-2 through the rollers of the production line. The X-ray emission machine 1 and the X-ray receiving machine 2 are used to collect the X-ray particle loss rate when the material passes through, and the host machine converts it into the real-time material thickness x.

[0031] Step 4: Operators monitor relevant data in real time. If any data exceeds the standard, the alarm will sound. Operators will then determine whether to stop the machine to test the sample. If no abnormalities are found, the continuous production line will be completed normally.

[0032] Step 5: After the measurement is completed, the operator saves the measurement data to the cloud, checks the equipment for any abnormalities, and shuts down the equipment.

[0033] When the foam material moves online through the detection platform, it must remain stable and taut.

[0034] In the above scheme, preferably, the mechanism presser foot 10 is fixed to the whole machine or the fixing mechanism is made of marble by bolts and nuts, the feed guide roller 3-1 and the discharge guide roller 3-2 are arranged horizontally and parallel, the feed reference roller 4-1 and the discharge reference roller 4-2 are arranged horizontally and parallel, and the feed reference roller 4-1 and the discharge reference roller 4-2 have the same weight.

[0035] In the above scheme, preferably, the foam material is sponge, composite leather, or composite sponge.

[0036] The material is divided into nine equal-width zones along the warp direction of the machine. A servo motor controlled by an electric system pulls the sensor head and receiver plate, setting the sensor's speed and trajectory to measure and process data from these nine zones. When the operator starts the main unit and inputs an electrical signal, the machine activates the X-ray detector. Simultaneously, the servo motor pulls the sensor head and receiver plate back and forth according to the set trajectory and speed, measuring the composite sponge, composite leather, and foam. The collected data is then displayed on the main unit for real-time feedback. Data from the end of each batch is categorized and stored in the main unit according to the batch number for easy retrieval and traceability. The system includes different levels of warning values ​​and corresponding measures. For minor thickness deviations, the system automatically adjusts and provides manual alerts. For larger thickness deviations, the system will immediately stop the production line after an alarm to prevent losses.

[0037] The results of testing the thickness of composite sponge, composite leather, and sponge according to this invention are shown in Table 1.

[0038]

Example 2

[0039] Sponge 2 was used as the test sample, and the specific method was the same as in the above embodiment; the specific test results are shown in Table 2.

[0040] Comparative Example 1

[0041] Composite sponge, composite leather, and sponge 1 were used as test samples, and their thickness was tested according to the steps in Chinese patent CN212620595U; the specific test results are shown in Table 1.

[0042] Comparative Example 2

[0043] Composite sponge, composite leather, and sponge 1 were used as test samples. The measured values ​​of the samples were tested using an electronic thickness gauge, which can be assumed to be the actual values. It is specifically used to measure the thickness of textiles. The principle is contact measurement. There is a force sensor on the probe. It stops immediately after contacting the object to ensure that the object is not deformed and the most accurate thickness value is measured. The specific test results are shown in Table 1.

[0044] Comparative Example 3

[0045] Using sponge 2 from Example 2 as the test sample, the sponge thickness was tested according to the steps in Chinese Patent CN212620595U; the specific test results are shown in Table 2.

[0046] Comparative Example 4

[0047] Using sponge 2 from Example 2 as the test sample, the test results were obtained according to the testing equipment of Chinese Patent CN212620595U, except that only the laser was replaced with X-rays, the pressure foot of the mechanism was not fixed, and no corresponding reference roller was set. The results are shown in Table 2.

[0048] Comparative Example 5

[0049] Using sponge 2 from Example 2 as the test sample, the thickness was measured using X-rays, but the test results for the fixed frame without fixing are shown in Table 2.

[0050] Table 1. Thickness test results of products made of different materials using different methods.

[0051]

[0052]

[0053] Table 2 Thickness test results of the same material using different test methods

[0054]

[0055] The above tests conclude that X-rays have the characteristics of high precision and wide applicability, and can be used for online thickness measurement of composite sponges, composite leathers, and foams.

[0056] Figures 5 to 7 The chart is based on Table 1. The measured values ​​have been rounded to two decimal places. The data from the electronic thickness gauge can be approximated as the actual thickness of the object. As can be seen from the chart, the product thickness results tested using this utility model are closer to the actual test results and can be flexibly applied to online production.

Claims

1. An online X-ray thickness measurement device, comprising: The X-ray emitting machine (1), X-ray receiving machine (2), feed guide roller (3-1), discharge guide roller (3-2), feed reference roller (4-1), discharge reference roller (4-2), linkage shaft (5), connecting rod (6), control panel (8), chassis frame (9), mechanism pressure foot (10), and test substrate (12) are described above. The X-ray emitting machine (1) includes a first drag chain (1-1), a first slide rail (1-2), a first fixed rod (1-3), a first lead screw (1-4), and an X-ray sensor. The X-ray receiving machine (2) includes a second drag chain (2-1), a second slide rail (2-2), a second fixing rod (2-3), a second lead screw (2-4), and an X-ray receiver (2-5). Both the X-ray emitting machine (1) and the X-ray receiving machine (2) are fixed to the chassis frame (9). The X-ray emitting machine (1) is integrated into the upper frame of the chassis frame (9), and the X-ray receiving machine (2) is integrated into the lower frame of the chassis frame (9). The two are positioned in the same direction. The integrated control system maintains a consistent position in real time; the feed guide roller (3-1) and discharge guide roller (3-2) are installed in the upper grooves of the left and right frames for feeding and discharging; the feed reference roller (4-1) and discharge reference roller (4-2) are installed in the lower grooves of the left and right frames; the linkage shaft (5) is located between the groove and the connecting rod (6), and is responsible for transmitting the torque of the motor built into the chassis frame (9) to the connecting rod (6) to drive the feed guide roller (3-1), discharge guide roller (3-2), and feed reference roller (4-1). The discharge reference roller (4-2); the control panel (8) is connected to the built-in host via a wire harness for manual interaction and data supervision; characterized in that the mechanism press foot (10) is fixed by bolts and nuts or the fixing mechanism is made of marble, the feed guide roller (3-1) and the discharge guide roller (3-2) are arranged horizontally and parallel, the feed reference roller (4-1) and the discharge reference roller (4-2) are arranged horizontally and parallel, and the feed reference roller (4-1) and the discharge reference roller (4-2) have the same weight.

2. The X-ray online thickness measurement device according to claim 1, characterized in that, The first slide rail (1-2) and the first lead screw (1-4) are both fixed inside the chassis frame (9), and the upper inner end of the first fixing rod (1-3) is fixedly connected to the other end of the first drag chain (1-1); the second slide rail (2-2) and the second lead screw (2-4) are both fixed inside the chassis frame (9), and the upper inner end of the second fixing rod (2-3) is fixedly connected to the other end of the second drag chain (2-1).

3. The X-ray online thickness measurement device according to claim 1, characterized in that, The X-ray emitting machine (1) uses a 30 KeV X-ray emitter and a gas ionization chamber / solid ionization detector in its sensing head.

4. The X-ray online thickness measurement device according to claim 1, characterized in that, The online thickness measuring device also includes an alarm (7) and a dust removal pipe (11); the alarm (7) is connected to the built-in host via a wiring harness and is used to issue an alarm for products that exceed specifications; the dust removal pipe (11) is fixed to the right frame by bolts and nuts.

5. The X-ray online thickness measurement device according to claim 1, characterized in that, The fixing mechanism includes a first slide rail (1-2), a first fixing rod (1-3), a second slide rail (2-2), a second fixing rod (2-3), a mechanism pressure foot (10), an overall base of the machine, a side slide rail, a support frame, and an internal support structure for the motor.

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