A thickness testing device applicable to different coatings

Abstract

This utility model relates to the field of coating thickness testing technology, and in particular to a thickness testing device applicable to different coatings. The device includes a housing and a thickness testing control structure mounted on the housing. The thickness testing control structure includes a sensing module, a non-magnetic material processing module, a magnetic material processing module, a main control module, a power supply module, and a Bluetooth module. The power supply module provides power to the sensing module, the non-magnetic material processing module, the magnetic material processing module, the main control module, and the Bluetooth module. This utility model provides a thickness testing device applicable to different coatings, capable of testing the thickness of various coatings. This not only improves work efficiency but also ensures product quality and reduces waste and losses caused by traditional testing methods.

Description

Technical Field

[0001] This utility model relates to the field of coating thickness testing technology, and in particular to a thickness testing device that can be used for different coatings. Background Technology

[0002] Before the invention of coating thickness gauges, measuring the thickness of anti-corrosion coatings on metal surfaces typically relied on destructive methods, such as scraping or grinding away portions of the coating to directly measure its thickness. This method was not only inefficient but also caused irreversible damage to the object being tested, limiting its widespread use in practical applications. Furthermore, this destructive testing method was clearly unsuitable for some high-value or difficult-to-repair workpieces.

[0003] To overcome the above problems, the industry urgently needs a technology that can accurately measure the thickness of a substrate's coating or plating without damaging the substrate surface. Summary of the Invention

[0004] This invention addresses the problems of existing technologies by providing a thickness testing device applicable to different coatings. It can test the thickness of different coatings, which not only improves work efficiency but also ensures product quality and reduces waste and losses caused by traditional testing methods.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a thickness testing device applicable to different coatings, comprising a housing and a thickness testing control structure mounted on the housing, wherein the thickness testing control structure comprises a sensing module, a non-magnetic material processing module, a magnetic material processing module, a main control module, a power supply module, and a Bluetooth module; the power supply module is used to supply power to the sensing module, the non-magnetic material processing module, the magnetic material processing module, the main control module, and the Bluetooth module;

[0006] The sensing module includes a first sensor and a second sensor. The first sensor is used to generate electromagnetic induction in magnetic materials, and the output terminal of the first sensor is connected to the input terminal of the magnetic material processing module. The second sensor is used to detect eddy current induction generated by non-magnetic materials, and the output terminal of the second sensor is connected to the input terminal of the non-magnetic material processing module.

[0007] The magnetic material processing module is used to convert the electromagnetic wave voltage detected by the first sensor into a frequency signal, and transmit the converted frequency signal to the main control module;

[0008] The non-magnetic material processing module is used to convert the eddy current effect voltage detected by the second sensor into a frequency signal, and transmit the converted frequency signal to the main control module;

[0009] The main control module is used to convert the received frequency signal into a thickness and transmit it to an external Bluetooth device through the Bluetooth module.

[0010] Preferably, the magnetic material processing module includes a magnetic controller U1, resistors R20, R18, R17, and R21. The W and B pins of the first sensor input electromagnetic induction signals through pin 9 of the magnetic controller U1. The B pin of the first sensor passes through resistors R20, R18, R17, and R21 in sequence, and enters pins 15 and 14 of the magnetic controller U1. The 16th pin of the magnetic controller U1 outputs a frequency signal to the main control module.

[0011] Preferably, the non-magnetic material processing module includes a non-magnetic controller U4, capacitors C36, C29, and C28, and an adjustable resistor VR2. A frequency oscillator is formed among the second sensor, the non-magnetic controller U4, capacitors C36, C29, and C28, and the adjustable resistor VR2. The 7th pin of the non-magnetic controller U4 outputs a frequency signal to the main control module.

[0012] Preferably, it also includes a buzzer module, the input of which is connected to the output of the main control module.

[0013] Preferably, the power module includes a battery unit, a switching unit, and a power conversion processing unit. The output terminal of the battery unit is connected to the input terminal of the power conversion processing unit through the switching unit, and the output terminal of the power conversion processing unit is used to provide the operating voltage.

[0014] Preferably, the housing is equipped with a display module, which is connected to the main control module and used to display the measurement results.

[0015] Preferably, the housing is equipped with a button module, which is connected to the main control module and is used to output measurement and control signals to the main control module.

[0016] Preferably, the first sensor includes a mounting bracket, a probe, and a metal component. The mounting bracket is mounted on the housing, the probe is mounted on the mounting bracket, and the metal component is fitted around the outer periphery of the probe. The probe is used to perform tests and transmit test data to the main control module.

[0017] Preferably, the end of the probe used for testing is equipped with a diamond contact.

[0018] The beneficial effects of this utility model are:

[0019] This utility model provides a thickness testing device that can be used for different coatings. The sensor is reliable and can test the coating thickness of different metal surfaces. It not only improves work efficiency but also ensures product quality, reduces waste and losses caused by traditional testing methods, is easy to use, low in cost, highly efficient, and highly reliable. In addition, it can be connected to Bluetooth devices via a Bluetooth module to transmit the test data results to the Bluetooth device for display, making it even more convenient to use. Attached Figure Description

[0020] Figure 1 This is a signal block diagram of the present invention;

[0021] Figure 2 The circuit diagrams are of the sensing module, magnetic material processing module and non-magnetic material processing module of this utility model.

[0022] Figure 3 This is a circuit diagram of the sensing module and magnetic material processing module of this utility model;

[0023] Figure 4 This is a circuit diagram of the sensing module and the non-magnetic material processing module of this utility model.

[0024] Figure 5 This is the circuit schematic diagram of the main control module of this utility model;

[0025] Figure 6 This is the circuit schematic diagram of the buzzer module of this utility model;

[0026] Figure 7 This is a circuit diagram of the button module of this utility model;

[0027] Figure 8 This is a circuit diagram of the display module of this utility model;

[0028] Figure 9 This is a circuit diagram of the power module of this utility model;

[0029] Figure 10 This is a schematic diagram of the structure of the first sensor of this utility model;

[0030] Figure 11 This is an exploded structural diagram of the first sensor of this utility model.

[0031] exist Figures 1 to 11 The reference numerals in the figures include:

[0032] 1-Mounting bracket, 2-Detector, 3-Metal component. Detailed Implementation

[0033] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention. The present invention will be described in detail below with reference to the accompanying drawings.

[0034] This embodiment provides a thickness testing device that can be used for different coatings, such as... Figures 1 to 9 The device includes a housing and a thickness testing control structure mounted on the housing. The thickness testing control structure includes a sensing module, a non-magnetic material processing module, a magnetic material processing module, a main control module, a power supply module, and a Bluetooth module. The power supply module is used to supply power to the sensing module, the non-magnetic material processing module, the magnetic material processing module, the main control module, and the Bluetooth module.

[0035] like Figures 6 to 8 As shown, this embodiment also includes a buzzer module, a button module, and a display module; for example... Figure 9 As shown, the power module includes a battery unit, a switching unit, and a power conversion processing unit. The output terminal of the battery unit is connected to the input terminal of the power conversion processing unit through the switching unit. The output terminal of the power conversion processing unit is used to provide the operating voltage. This is prior art and will not be described in detail in this embodiment.

[0036] The sensing module in this embodiment includes a first sensor (WB) and a second sensor (YR). The first sensor is used to generate electromagnetic induction in magnetic materials, and the output terminal of the first sensor is connected to the input terminal of the magnetic material processing module. The second sensor is used to detect eddy current induction generated by non-magnetic materials, and the output terminal of the second sensor is connected to the input terminal of the non-magnetic material processing module.

[0037] The magnetic material processing module converts the electromagnetic wave voltage detected by the first sensor into a frequency signal and transmits the converted frequency signal to the main control module. The non-magnetic material processing module converts the eddy current effect voltage detected by the second sensor into a frequency signal and transmits the converted frequency signal to the main control module. The main control module converts the received frequency signal into thickness and transmits it to an external Bluetooth device via the Bluetooth module. Real-time uploading of measurement data to the mobile phone via the Bluetooth module avoids errors caused by manual data recording and misjudgments due to insufficient human experience.

[0038] Specifically, the specific circuit connection schematic diagram of this embodiment is as follows: Figures 2 to 9 As shown, this embodiment uses both magnetic and eddy current principles to measure the thickness of plating, paint, and insulation on metal surfaces.

[0039] In this embodiment, the thickness of the non-conductive coating layer on a non-magnetic metal substrate is measured. An electromagnetic field is generated in the probe sensor coil using a high-frequency AC signal from an NFe probe. When the probe approaches the conductor, eddy currents are formed within it. The closer the probe is to the conductive substrate, the larger the eddy currents and the greater the reflected impedance. This feedback effect characterizes the distance between the probe and the conductive substrate, which is equivalent to the thickness of the non-conductive coating layer on the conductive substrate.

[0040] A: Coating thickness gauges measure the thickness of non-magnetic coatings on magnetic metal substrates. The thickness of the coating is determined by the magnitude of the magnetic flux flowing from the sensor through the non-ferromagnetic coating into the ferromagnetic substrate using an Fe probe.

[0041] B: The coating thickness gauge measures the thickness of the non-magnetic NFe by pressing the sensor onto the surface of the object being measured. The Hall sensor inside the telescopic sensor generates an eddy current effect on the thickness of the object's surface and the surface of the object being measured.

[0042] The alternating current and voltage generated by the above two types of effects are converted into AC signals by the "VF conversion circuit (VF is a voltage-to-frequency circuit)," namely the magnetic material processing module and the non-magnetic material processing module, which are two VF conversion circuits. The main control module outputs a frequency identification signal, which is captured and measured by the PCA of the main control module, and the frequency is measured by the counter built into the main control module.

[0043] Thickness calibration: In this embodiment, a Hall sensor is used to measure signals of different coating thicknesses on a magnetic metal surface, obtaining the Hall induced voltage A and the current B passing through the Hall element. After temperature compensation, the relationship curve between XF and thickness SF is obtained. An eddy current effect sensor of the probe is used to measure signals of different coating thicknesses on a non-magnetic metal surface, obtaining the AC frequency C of the eddy current coil and the current D passing through the Hall element. After temperature compensation, the relationship curve between WF and thickness WS is obtained. The curve data is stored on the device, and the thickness, curve, and compensation method are obtained through weighted calculation. These are all existing technologies and will not be elaborated here, but are presented as a feasible method for testing thickness calibration.

[0044] like Figures 1 to 9 As shown, the specific working principle of this embodiment is as follows:

[0045] 1) By utilizing the principles of electromagnetic induction and eddy current induction, the electromagnetic induction and eddy current induction intensity of the coating thickness on the metal surface are measured.

[0046] 2) Signal flow direction: First sensor WB;

[0047] 3) The first sensor WB winding generates electromagnetic induction to detect magnetic materials, while the second sensor YR winding generates eddy current induction to detect non-magnetic materials.

[0048] 4) Circuit working principle:

[0049] 1. Model: U1 is TLC2254, U4 is CD4060, U5 is ME3116, U6 is OM6626A;

[0050] 2. For example Figures 2 to 5 The first sensor, WB, works in conjunction with U1 to detect magnetic materials and metals. It uses the principle of magnetic induction and performs a VF (voltage-to-frequency conversion) on the sensor's signal voltage, converting the electromagnetic wave voltage into a frequency signal. The W and B pins of the first sensor input the electromagnetic induction signal through pin 9 of U1, and simultaneously, along with pin B, it passes through resistors R20, R18, R17, and R21 to pins 15 and 14 of U1. Pin 4 serves as the electromagnetic induction input resonant signal. The signals from pins 13, 10, and 7 of U1 are then internally shaped to form the VF conversion signal. This signal is then output as a frequency signal through pin 16 of U1 for calculation by U6.

[0051] 3. For example Figure 4 The sensor YR and U4 work together to detect non-magnetic materials, utilizing the eddy current effect principle. The sensor's signal voltage undergoes a VF conversion (eddy current voltage-to-frequency conversion), converting the eddy current voltage into a frequency signal. The second sensor, U4, C36, C29, C28, and VR2 form a frequency oscillator. The electromagnetic design of the second sensor YR fully leverages the characteristics of the U44060 IC. The U44060 consists of an oscillator and a 14-bit binary serial counter. The oscillator can be an RC or crystal circuit. When CR is high, the counter is cleared and the oscillator is disabled. All counter bits are master-slave flip-flops. The counter counts in binary on the falling edge of CP1 (and CP0). A Schmitt trigger is used on the clock pulse line to limit the rise and fall times of the clock. The electromagnetic design of sensor YR, combined with the 4060, generates a high-quality and accurate frequency oscillation signal. After VF conversion, the frequency signal is transmitted to U6 via pin 7 of U4 and R32.

[0052] 4. U5 is the power management chip, responsible for providing high-quality, high-efficiency power to the entire product. U6 is the main control module; the schematic diagram of U6 is shown below. Figure 5As shown, the preferred model is OM6626A, which realizes key recognition analysis, calculation after sensor signal acquisition, display character library and menu analysis, Bluetooth protocol connection, and Bluetooth output to mobile APP. It can use mobile phone and APP to organize, save, upload to the cloud, and output data. The analysis and calculation mentioned above are all existing technologies, and will not be described in detail in this embodiment. For example, the two frequency signals are respectively connected to pins 2 and 3 of the main control module U6. Pins 2 and 3 of the main control module U6 are two PCA modules used to capture frequency signals. The frequency is captured by the internal PCA module of the main control module U6 (the PCA module built into the main control module is existing technology and is built into the main control module). Combined with the piecewise linear calibration analysis built into the main control module (existing technology, not described here), the main control module U6 can convert the frequency signal into a thickness value.

[0053] like Figure 10 and Figure 11 In this embodiment, the first and second sensors have similar structures, including a mounting bracket 1, a probe 2, and a metal part 3. The mounting bracket 1 is mounted on the outer shell, the probe 2 is mounted on the mounting bracket 1, and the metal part 3 is sleeved around the outer periphery of the probe 2. The probe 2 is used for testing and transmitting test data to the main control module. Preferably, the end of the probe 2 used for testing is equipped with a diamond contact.

[0054] Specifically, the metal component 3 serves to shield and prevent interference, making the detection and transmission of data more accurate. While the structure of the detector 2 is based on existing technology, this embodiment equips the head of the detector 2, the end used for detection, with a diamond contact made of diamond. Diamond has high hardness and is more wear-resistant than commercially available metal contacts, thus improving the service life of this embodiment. Furthermore, the detector 2 in this embodiment is made of black ferrite and integrates a special magnetic alloy material. This material's magnetism can magnetically inductively induce the metal coatings of cold-dip galvanizing and hot-dip galvanizing, thereby detecting the thickness of the zinc-plated anti-corrosion coating in the electroplating industry. Since the anti-corrosion coating is primarily a zinc coating, and zinc itself is metallic, the first and second sensors in this embodiment can identify it.

[0055] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some changes or modifications to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the present utility model without departing from the scope of the present utility model shall fall within the scope of the present utility model.

Claims

1. A thickness testing device applicable to different coatings, characterized in that: The device includes a housing and a thickness testing control structure mounted on the housing. The thickness testing control structure includes a sensing module, a non-magnetic material processing module, a magnetic material processing module, a main control module, a power supply module, and a Bluetooth module. The power supply module is used to supply power to the sensing module, the non-magnetic material processing module, the magnetic material processing module, the main control module, and the Bluetooth module. The sensing module includes a first sensor and a second sensor. The first sensor is used to generate electromagnetic induction in magnetic materials, and the output terminal of the first sensor is connected to the input terminal of the magnetic material processing module. The second sensor is used to detect eddy current induction generated by non-magnetic materials, and the output terminal of the second sensor is connected to the input terminal of the non-magnetic material processing module. The magnetic material processing module is used to convert the electromagnetic wave voltage detected by the first sensor into a frequency signal, and transmit the converted frequency signal to the main control module; The non-magnetic material processing module is used to convert the eddy current effect voltage detected by the second sensor into a frequency signal, and transmit the converted frequency signal to the main control module; The main control module is used to convert the received frequency signal into a thickness and transmit it to an external Bluetooth device through the Bluetooth module.

2. The thickness testing device for different coatings according to claim 1, characterized in that: The magnetic material processing module includes a magnetic controller U1, resistors R20, R18, R17, and R21. The W and B pins of the first sensor input electromagnetic induction signals through pin 9 of the magnetic controller U1. The B pin of the first sensor passes through resistors R20, R18, R17, and R21 in sequence, and enters pins 15 and 14 of the magnetic controller U1. Pin 16 of the magnetic controller U1 outputs a frequency signal to the main control module.

3. The thickness testing device for different coatings according to claim 1, characterized in that: The non-magnetic material processing module includes a non-magnetic controller U4, capacitors C36, C29, and C28, and an adjustable resistor VR2. A frequency oscillator is formed between the second sensor, the non-magnetic controller U4, capacitors C36, C29, and C28, and the adjustable resistor VR2. The 7th pin of the non-magnetic controller U4 outputs a frequency signal to the main control module.

4. The thickness testing device for different coatings according to claim 1, characterized in that: It also includes a buzzer module, the input of which is connected to the output of the main control module.

5. The thickness testing device for different coatings according to claim 1, characterized in that: The power module includes a battery unit, a switching unit, and a power conversion processing unit. The output terminal of the battery unit is connected to the input terminal of the power conversion processing unit through the switching unit. The output terminal of the power conversion processing unit is used to provide the operating voltage.

6. The thickness testing device for different coatings according to claim 1, characterized in that: The housing is equipped with a display module, which is connected to the main control module and is used to display measurement results.

7. The thickness testing device for different coatings according to claim 1, characterized in that: The housing is equipped with a button module, which is connected to the main control module. The button module is used to output measurement and control signals to the main control module.

8. The thickness testing device for different coatings according to claim 1, characterized in that: The first sensor includes a mounting bracket, a probe, and a metal component. The mounting bracket is mounted on the housing, the probe is mounted on the mounting bracket, and the metal component is fitted around the outer periphery of the probe. The probe is used to perform tests and transmit test data to the main control module.

9. The thickness testing device for different coatings according to claim 8, characterized in that: The end of the probe used for testing is equipped with a diamond contact.

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