Rotating Hardness Tester Head for Inclined Surface Testing
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Solution Overview
Problem
Current hardness testers are inadequate for performing precise three-dimensional hardness tests on large and inclined pieces, as they require moving heavy and bulky objects, which is costly and impractical, and existing solutions like portal testers can only test from the top, limiting precision and accessibility.
Innovation Solution
A hardness tester with a rotating measuring head that can rotate around multiple axes (X, Y, Z) and is secured to inclined revolving devices, allowing it to move linearly and adjust to any angle, enabling tests on all surfaces and angles, including spheres from bottom to top, with a milling device, load cell, camera, and hydraulic brakes for precise measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual grinding is used to flatten the test point, then the surface can be prepared for testing, but heating occurs at the test point which alters the hardness and causes operator fatigue
Solution Approach 1:
The patent replaces manual mechanical grinding with an automated grinding wheel system that is part of the hardness tester. This automated system controls the grinding process precisely, preventing excessive heat generation that would alter the material's hardness, while also eliminating operator fatigue associated with manual grinding.
2Ease of operation
If portable hardness testers are used to get closer to the piece, then accessibility is improved, but precision is lost as 29,436 N of thrust cannot be performed without a reaction point
Solution Approach 1:
The patent creates a universal testing system that combines the accessibility of portable testers with the measurement precision of fixed installations. The hardness tester with rotating head can reach any surface of large pieces while maintaining the full 29,436 N thrust capability through its portal mounting system, eliminating the precision limitations of portable devices.
3Measurement precision
If portal hardness testers are used to exert 29,436 N force, then measurement precision is improved, but excessively large pieces cannot be tested as the piece must be turned to test sides, which is not always possible
Solution Approach 1:
The patent introduces dynamic positioning capabilities through a rotating head mounted on a tilting system with multiple rotational axes. This allows the testing apparatus to adapt its orientation to match any surface angle of large pieces, enabling precise 29,436 N hardness tests on previously inaccessible areas without requiring the piece to be moved or repositioned.
4Ease of manufacture
If pieces are flattened on the test point using manual grinding, then the test can be performed, but considerable operator fatigue occurs and inaccuracy in grinding depth is introduced
Solution Approach 1:
The patent implements a self-service automated grinding system where the grinding wheel is integrated into the hardness tester itself. The system automatically performs the flattening operation with controlled depth, eliminating operator fatigue and ensuring consistent, accurate grinding depth without requiring manual intervention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise three-dimensional hardness testing on large and inclined pieces without the need to move the pieces, allowing tests on any point, including sides and angles, with improved precision and reduced operator fatigue, and can exert a force of 29,436 N for accurate measurements.
Implementation Method 1
a first hydraulic brake suitable for blocking the rotation of the rotating measuring head around said axis (Y) to counterbalance the thrust forces
Implementation Method 2
a first hydraulic brake suitable for blocking the rotation of the rotating measuring head around said axis (Y) to counterbalance the thrust forces
Implementation Method 3
a load cell, called indenter, for carrying out the hardness test
Data Source
AI summary
The present invention refers to a hardness tester provided with a rotating measuring head, a first rotating device and a second rotating device, wherein said rotating measuring head is secured to said rotating device and is capable of rotating with respect to it, and wherein said first rotating device and said second rotating device are secured to each other and inclined with respect to each other.In this way, thanks to the combination of the two angles of the rotating devices with respect to the rotating measuring head, the head itself is allowed to rotate in space with an infinite variety of angles. It is thus possible to carry out tests both above and along the sides of the pieces to be tested, and also on each inclined point, in practice, with a three-dimensional system.In particular, the hardness tester is equipped with a slide provided with a stroke on which the rotating measuring head is mounted and with a first motor capable of activating the movement of the slide.In the present invention, the rotating head is moved so as to reach any point of the piece to be measured.In this way, the problem of having to move the pieces to be measured, often extremely heavy and bulky, remaining instead stationary, is solved.