SCB-3.0 XYZ Fully Automatic Small Load Brinell Hardness Tester

1.Overview

With the increasing diversification of workpiece specifications and personalized testing processes in industrial manufacturing, traditional fully automatic hardness testers are struggling to adapt to flexible testing scenarios. This solution builds on head-down automatic testing and intelligent data management by adding customizable automatic testing programming capabilities. This creates a fully automatic Brinell hardness tester that integrates flexible programming, automatic testing, precise calculations, and intelligent management. This solution meets the hardness testing needs of a wide range of workpieces made of metal materials (such as steel, cast iron, and non-ferrous metals), enabling personalized testing processes, standardized data management, and diversified result output. It is deeply integrated with intelligent factory production systems, enhancing testing flexibility and production adaptability.

2. Core Functional Module Design

(1) Fully automatic measurement

1. Automatic force application and indentation formation: The equipment is equipped with a high-precision servo force application system, which automatically applies the corresponding test force according to the preset test standard. After unloadingis completed, the test force is removed to form a standard indentation. No manual operation is required throughout the process.
2. Intelligent image recognition: A 300W pixel CMOS camera with a dedicated optical lens automatically focuses on the indentation area, identifies the indentation boundary through image algorithms, and accurately measures the indentation diameter.

(2) Hardness conversion

The Brinell hardness value (HB) obtained from the test can be automatically converted to Rockwell hardness (HR) and Vickers hardness (HV). Users can manually select the target hardness unit on the operation interface, and the system displays the conversion results in real time to ensure data accuracy.

(3) Data management

1. Massive database storage: The device has a built-in large-capacity local database that supports automatic storage of all test data (including hardness value, test force, indentation size, test time, tester, product name) and corresponding indentation images. There is no upper limit on data storage and it supports regular backup to external storage devices (such as USB flash drives and hard drives) to prevent data loss.
2. Multi-dimensional data query: Provides flexible query functions. Users can query historical data through single or combined conditions such as “tester”, “test time (accurate to the minute)”, “product name”, “hardness range”, etc. The query results display data details and corresponding indentation images in real time, supporting rapid location of target detection records.
3. Diversified data reports: Supports exporting test data into WORD or EXCEL format reports, which include test items, data lists, statistical analysis (such as average value, standard deviation), etc.; also supports external printers to achieve instant report printing, which is convenient for archiving, auditing and employee training.

(4) Communication interface

The device uses the HTTP communication protocol and defines a fixed data upload format (the data frame contains the following fields: device number, product number, test timestamp, hardness value (HB/HR/HV), indentation size, and test result judgment (pass/fail)). Users can set parameters such as the IP address and port number through the device operation interface to achieve seamless connection with the factory host system, meeting intelligent needs such as real-time data monitoring and production report statistics.

3. Equipment Workflow

1. Sample preparation: Place the workpiece to be tested on the equipment stage.
2. Parameter setting: Select the test scale (such as HBW 2.5/62.5), product name, and tester information on the operation interface,programming testing is supported.
3. Automatic detection: After the equipment is started, the pressurizing mechanism is automatically moved to the detection position, loading→ dwell → unloading. At the same time, the industrial camera captures the indentation image.
4. Data processing: The system automatically identifies the indentation size, calculates the Brinell hardness value, converts it to HR/HV as required, and simultaneously determines the test result (compared with the preset qualified range).
5. Data storage and output: test data and indentation images are automatically saved to the database. Users can choose to export reports, print results, or upload them to the factory system via the http interface.
6. Next round of inspection: Automatic reset, new workpiece can be placed in and the above process can be repeated to achieve batch continuous inspection.

4.Product Parameters

Measuring range: 8-650 HBW

Test force options: 31.25kgf (306.5N), 62.5kgf (612.9N)

Maximum allowable height of specimen: Maximum height of workpiece 150mm (700mm can be customized)

Throat: 170mm (can be customized as needed)

XY electric platform travel: 150X100mm (can be customized as needed)

Objective magnification: 2.5×, 5×

Hardness value resolution: 0.1HBW, 0.005mm

Measurement method: automatic measurement

Dwell time: 0-90S

Loading method: cell load

Turret mode: automatic turret

5. Software

Brinell indentation measurement system

The measuring system can control the movement and measurement of the hardness tester, such as: main machine turret, test force change, light brightness and other functions.

Measurement method: Indentation measurement methods include fully automatic measurement, circle measurement, and line measurement.

Hardness conversion: The measured Brinell hardness value can be converted into other hardness values according to American or international standards, such as HV, HRA, HRB, HRC, HR15N, HR30N, HR45N, HR15T, HR30T, HR45T, etc.

Statistical results: Maximum value, minimum value, average value, standard deviation, Cp, Cpk and other data are automatically generated, and the upper and lower limit values are automatically marked.

Test report: The software will automatically generate a report in Microsoft Word format, including measurement data, statistical results and measurement pictures.

6.Product Configuration: