Automatic process control system for ceramic coating oriented to the anti-oxidation function of prebaked anodes

Abstract

The application discloses an automatic process control system for ceramic coating of prebaked anode anti-oxidation function and relates to the technical field of spraying control.The system comprises a prebaked anode spraying pretreatment module, a spraying fluctuation monitoring module, a spraying fluctuation correction optimization module and a post-spraying treatment module.The application sprays the prebaked anode carbon block by means of an automatic spraying robot, monitors the fluctuation of the end spraying gun in real time according to the built-in driver of the automatic spraying robot, realizes preliminary judgment of spraying gun movement fluctuation and determines whether to execute auxiliary judgment of spraying gun movement, then determines whether to perform robot spraying correction based on the result of the auxiliary judgment of spraying gun movement, and finally conveys the prebaked anode carbon block after spraying to a flash drying area for flash drying and then performs primer spraying, thereby improving the adhesion of the ceramic coating to the prebaked anode, and solving the problem that the ceramic coating control is not accurate in the prior art, which further affects the anti-oxidation effect of the prebaked anode carbon block.

Description

Technical Field

[0001] This invention relates to the field of spraying control technology, and in particular to an automated process control system for ceramic coatings with prebaked anode anti-oxidation function. Background Technology

[0002] The construction of smart factories for prebaked anodes is an important trend in the aluminum industry. At the same time, the widespread application of automated equipment for prebaked anode production (such as spraying and feeding robots, cleaning production lines, etc.) has further improved production efficiency and product quality. Currently, the existing related automated process control systems are mainly implemented from three aspects: materials, coating processes, and automated equipment.

[0003] The automated spraying process is as follows: First, the anode carbon blocks are automatically transported to the dust removal chamber on a conveyor belt. The equipment automatically senses the workpiece and transports the carbon blocks to the cleaning station. After the workpiece stabilizes, an air knife cleans the dust off the surface of the carbon blocks, and the dust removal system collects all the dust. Next, the system automatically transports the carbon blocks to the spraying station. A hydraulic device above the carbon blocks automatically places a baffle above the anode carbon bowl to prevent paint mist from falling into the bowl. The robot automatically sprays the carbon blocks, and the system automatically cleans the spray gun after spraying. Then, the system automatically transports the carbon blocks coated with the base coat to the flash-drying station. Under the action of the air knife, the coating dries rapidly, meeting the basic conditions for continuing to spray the top coat. At the same time, the system automatically transports the flash-dried carbon blocks to the top coat spraying area. A hydraulic device above the carbon blocks automatically places a baffle above the anode carbon bowl to prevent paint mist from falling into the bowl, and the robot automatically sprays the carbon blocks. Finally, the system automatically transports the carbon blocks coated with the top coat to the drying area for drying.

[0004] For example, Chinese invention patent CN119148614B discloses an automatic programming spraying control system based on intelligent vision recognition, which includes: an automatic programming spraying area division module, an automatic programming spraying data acquisition module, an automatic programming spraying data analysis module, an automatic programming spraying control module, an automatic programming spraying comprehensive analysis module, and an automatic programming spraying human-computer interaction module; the automatic programming spraying area division module is used to take the object to be sprayed as the target area and divide the target area into several monitoring sub-areas according to each spraying object.

[0005] For example, the robot spraying control method, device, electronic device, and storage medium disclosed in Chinese invention patent CN114063570B include: obtaining the coordinates of spraying path points on the workpiece surface based on a grating spraying method; obtaining the time interval information between two adjacent spraying path points; obtaining constraint information; the constraint information includes the maximum paint film thickness, the maximum moving speed, and the maximum acceleration; and optimizing the time interval information using a particle swarm optimization algorithm based on the spraying path point coordinates, time interval information, and constraint information to minimize the target parameter; the target parameter is a function of the variance of the paint film thickness of the spraying path points, the variance of the total spraying time, and the variance of the time interval information.

[0006] The above-mentioned technology has at least the following technical problems:

[0007] Because ceramic coatings are inherently brittle, their thermal expansion under high-temperature conditions is mismatched with that of the carbon anode, making the coating prone to cracking or peeling. If the thickness of the coating is not precisely controlled by the robot, excessive thickness will exacerbate cracking, while insufficient thickness will render it ineffective. Therefore, the precision of the robot's coating thickness control determines the protective effect of the ceramic coating on the prebaked anode. Inaccurate thickness control is often the result of multiple coupled factors. Among these, real-time interference during the spraying process, such as the stretching of flexible tubing during robot movement causing slight fluctuations in joint speed, or the flow pulses and slight weight changes that occur when the spray is turned on and off, can easily affect the stability of the robot's movement, causing fluctuations in the spray gun's movement speed. This affects the thickness of the ceramic coating applied to the prebaked anode carbon block, and consequently, the anti-oxidation effect of the ceramic coating on the prebaked anode carbon block. Summary of the Invention

[0008] To address the technical problem of inaccurate control of ceramic coatings in existing technologies, which consequently affects the anti-oxidation effect of prebaked anode carbon blocks, this invention provides an automated process control system for ceramic coatings aimed at the anti-oxidation function of prebaked anodes. The technical solution is as follows:

[0009] This invention provides an automated process control system for ceramic coatings with prebaked anodes for anti-oxidation function. Specifically, it includes: a prebaked anode spraying pretreatment module, a spraying fluctuation monitoring module, a spraying fluctuation correction and optimization module, and a spraying post-treatment module. The prebaked anode spraying pretreatment module automatically transports the prebaked anode carbon blocks on a conveyor belt to a dust removal chamber for dust removal, then automatically transports the prebaked anode carbon blocks to the spraying station for topcoat spraying of the ceramic coating, and an automated spraying robot sprays the prebaked anode carbon blocks. The spraying fluctuation monitoring module monitors the spraying fluctuations based on the performance of the automated spraying robot. The built-in driver monitors the fluctuation of the end spray gun in real time, makes a preliminary judgment on the fluctuation of the spray gun movement to initially determine the probability of the spray gun fluctuation, and determines whether to perform spray gun movement auxiliary judgment to verify whether the spray gun movement has fluctuation; the spraying fluctuation correction and optimization module is used to determine whether to perform robot spraying correction based on the result of the spray gun movement auxiliary judgment to improve the stability of the end spray gun movement of the spraying robot; the spraying post-processing module is used to transport the sprayed prebaked anode carbon block to the flash drying area, and after flash drying, the prebaked anode carbon block is transported to the next spraying station for ceramic coating primer spraying.

[0010] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following:

[0011] 1. The automatic spraying robot's built-in driver monitors the fluctuations of the end-effector spray gun in real time. Dynamically collecting the spray gun's movement status during the spraying process helps identify potential instability early on. A preliminary judgment of the spray gun's movement fluctuations is then performed to initially assess the probability of fluctuations. This helps avoid the problem in traditional technologies where spray gun movement fluctuations are only detected after coating defects appear. Simultaneously, it determines whether to perform auxiliary judgment to verify the presence of fluctuations. Based on the results of the auxiliary judgment, it determines whether robot spraying correction is needed, thereby improving the stability of the end-effector spray gun's movement. This more accurately verifies whether the automatic spraying robot's spray gun movement speed fluctuates abnormally, preventing the lack of multi-level judgment mechanisms in existing systems that lead to frequent false alarms or missed detections on the production line. This effectively solves the problem in existing technologies where abnormal spray gun movement speed fluctuations lead to inaccurate control of the ceramic coating, thus affecting the anti-oxidation effect of the prebaked anode carbon block.

[0012] 2. Statistical analysis of excessive linear velocity fluctuations, excessive angular velocity fluctuations, and excessive time points for both linear and angular velocity fluctuations yields an index for excessive spray gun movement speed fluctuations. This not only more accurately quantifies the quality of the spray gun trajectory but also helps to understand the duration and frequency of abnormal spray gun movement speed fluctuations. This prevents false alarms and missed alarms caused by traditional methods that rely solely on single threshold alarms and cannot distinguish between "short-term transient noise" and "continuous fluctuations." Then, a comprehensive value for excessive linear velocity fluctuations is obtained based on the length of the excessive linear velocity fluctuation segment and the number of excessive linear velocity time points. Similarly, a comprehensive value for excessive angular velocity fluctuations is obtained based on the length of the excessive angular velocity fluctuation segment and the number of excessive angular velocity time points. Finally, a preliminary judgment value for spray gun movement fluctuations is derived based on both the comprehensive values ​​for linear and angular velocity fluctuations. By integrating multi-dimensional indicators into a single comparable value, rapid judgment and threshold comparison are facilitated, aiding in real-time decision-making. The preliminary judgment value for spray gun movement fluctuations is then compared with... The spray gun motion fluctuation threshold is compared. If the initial judgment value of the spray gun motion fluctuation is greater than the spray gun motion fluctuation threshold, the driver current is introduced for auxiliary verification and judgment to improve the judgment confidence. At the same time, robot spraying prevention measures are activated to intervene in advance in case of possible abnormal fluctuations in robot motion speed. This optimizes the shortcomings of the traditional strategy, which either continues to run, resulting in a large number of defects, or completely shuts down, affecting production capacity, and has no intermediate "soft prevention" strategy. Otherwise, the next spraying cycle is monitored, and fluctuation trend change analysis is performed to detect abnormal fluctuations in robot motion speed in a timely manner, and then intervene in advance to reduce the impact of abnormal fluctuations in robot motion speed on the ceramic coating spraying of prebaked anodes. By continuously recording the fluctuation change trend, not only can parameter fine-tuning be performed in advance to reduce the sudden failure rate, but it also helps to make up for the shortcomings of traditional threshold-based systems, which are prone to frequent false alarms or premature shutdowns, and cannot achieve "early warning before shutdown" without trend analysis.

[0013] 3. The percentage change of the spray gun movement speed fluctuation exceeding the standard index and the spray gun movement speed fluctuation exceeding the standard index in the next spraying cycle are quantified separately to obtain the corresponding fluctuation change rate. This helps to distinguish between "temporarily stable fluctuation" and "continuously aggravated fluctuation", thus achieving dynamic trend perception and filling the gap in the existing system where the lack of trend quantification leads to delayed triggering of preventive measures and the inability to intervene in advance. Then, the fluctuation change rate is comprehensively quantified to obtain the total change rate value, and the total change rate value is compared with the change rate judgment value. However, the existing technology trigger control is often binary and lacks progressive and differentiated control. By comparing the change rate judgment, it is helpful to promptly detect the abnormal trend of fluctuation and trigger it immediately. The corresponding measures are as follows: if the total rate of change is greater than the rate of change judgment value, the robot spraying prevention measures are activated, and the corresponding spraying prevention amplitude is mapped to compensate for the robot correction frequency. The robot correction frequency is adjusted, and the fluctuation of the automatic spraying robot speed is corrected by adjusting the robot correction frequency. This achieves adaptive adjustment of the spray gun control parameters, ensures the stability of the spray gun movement, and solves the problem that the correction frequency of the current traditional system is fixed and it is difficult to match different degrees of fluctuation. Otherwise, the next spraying cycle is monitored, and the fluctuation trend change analysis is performed. By continuously monitoring and executing the fluctuation trend change analysis, predictive maintenance of the long-term change trend of the spray gun movement speed fluctuation is achieved. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the structure of an automated process control system for ceramic coatings with prebaked anode anti-oxidation function provided in an embodiment of the present invention;

[0016] Figure 2 This is a schematic diagram of the process for marking out-of-standard points provided in an embodiment of the present invention;

[0017] Figure 3 This is a schematic diagram of the process for preliminary judgment of spray gun movement fluctuations provided in an embodiment of the present invention. Detailed Implementation

[0018] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0019] In embodiments of the present invention, words such as "exemplarily," "for example," etc., are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" in the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the word "exemplary" is intended to present the concept in a concrete manner. Furthermore, in embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one.

[0020] In the embodiments of this invention, the terms "image" and "picture" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning. Similarly, the terms "of," "corresponding (relevant)," and "corresponding" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning.

[0021] In this embodiment of the invention, sometimes a subscript such as W1 may be written in a non-subscript form such as W1. When the difference is not emphasized, the meaning they express is the same.

[0022] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0023] An automated process control system for ceramic coatings with prebaked anodes for anti-oxidation function typically includes the following processes: raw material and coating preparation, anode surface pretreatment, automatic spraying and coating, drying and initial curing, high-temperature curing, and finished product inspection.

[0024] The raw material and coating preparation involves selecting ceramic powders such as alumina, zirconium oxide, and silicon oxide, or composite nano-ceramic materials, and adding inorganic / organic binders, solvents, dispersants, and leveling agents to create a sprayable slurry. Simultaneously, particle size distribution and viscosity must be controlled to suit the spraying equipment. Anode surface pretreatment involves mechanical grinding, blowing, or sandblasting to remove dust and loose particles, and, if necessary, surface heating or drying to ensure the substrate is clean and dry, improving adhesion. Automatic spraying and coating utilize automatic spray guns or spraying robots to evenly cover the sides or top of the prebaked anode with ceramic coating. The coating thickness is mainly controlled by… The spray gun movement speed (usually a fixed program setting), the number of sprays (multiple layers), and the paint flow rate (controlled by valves or pumps) are all important parameters. Drying and initial curing refer to the process of sending the coating to a drying area or using hot air to remove moisture or solvents after the coating is completed. At the same time, the drying temperature and time must be controlled to avoid cracking or peeling. High-temperature curing refers to heating at a temperature above 400°C to reduce the gaps between ceramic particles and densify the coating. After high-temperature treatment, the pores in the coating are smaller than the diameter of gas molecules, forming an effective barrier layer. Finally, the finished product is inspected by manual or sampling thickness measurement (such as magnetic induction or laser scanning) to check whether the coating is uniform and whether there is any peeling or cracking.

[0025] This invention provides an automated process control system for ceramic coatings with prebaked anode anti-oxidation function. For example... Figure 1 The diagram shown is a schematic representation of the structure of an automated process control system for ceramic coatings with prebaked anode anti-oxidation function provided in an embodiment of the present invention. The system's processing flow includes the following modules: a prebaked anode spraying pretreatment module, a spraying fluctuation monitoring module, a spraying fluctuation correction and optimization module, and a spraying posttreatment module.

[0026] The prebaked anode spraying pretreatment module is used to automatically transport the prebaked anode carbon blocks on a plate chain to the dust removal chamber for dust removal. Then, it automatically transports the prebaked anode carbon blocks to the spraying station for ceramic coating topcoat spraying, and the prebaked anode carbon blocks are sprayed by an automatic spraying robot.

[0027] It should be noted that the ceramic coating acts as a protective barrier during the electrolytic aluminum process, reducing direct contact between the anode carbon block and air or electrolyte, thus reducing oxidation consumption. Simultaneously, the coating reduces oxidation erosion and structural damage to the carbon block, thereby decreasing the frequency of anode replacement, reducing anode carbon consumption and scrap, improving anode utilization, and lowering overall production energy consumption. Through automated and intelligent ceramic coating spraying and control processes, a stable, uniform, and high-quality anti-oxidation protective coating is provided to the prebaked anode, thereby extending anode life, reducing carbon consumption and emissions, and ensuring efficient, stable, and green operation of electrolytic aluminum production.

[0028] The spraying fluctuation monitoring module is used to monitor the fluctuation of the end spray gun in real time according to the built-in driver of the automatic spraying robot, make a preliminary judgment on the fluctuation of the spray gun movement to initially determine the probability of the spray gun having fluctuation, and determine whether to perform auxiliary judgment on the spray gun movement to verify whether the spray gun movement has fluctuation.

[0029] The spraying fluctuation correction and optimization module is used to determine whether to perform robot spraying correction based on the results of spray gun motion auxiliary judgment in order to improve the stability of the end spray gun motion of the spraying robot.

[0030] The post-coating module is used to transport the prebaked anode carbon block that has been coated to the flash-drying area. After flash-drying, the prebaked anode carbon block is transported to the next coating station for the primer coating of the ceramic coating.

[0031] In this embodiment, by automatically transporting the prebaked anode carbon blocks to the dust removal chamber on a plate chain for dust removal, the surface of the prebaked anode carbon blocks is kept clean, preventing dust from affecting the coating adhesion. Continuous production is also achieved, avoiding human positioning errors and improving the consistency of anode spraying. Simultaneously, the topcoat layer provides a preliminary protective barrier and a bonding interface with the primer. The automated spraying robot can achieve precise path control, ensuring uniform spray thickness and surface coverage, reducing human operation errors and labor intensity. Furthermore, the dynamic acquisition of the spray gun's movement status during spraying helps to identify potential instability in advance, preventing the accumulation of large-scale quality problems before they are discovered. Multi-dimensional judgment of the spray gun's movement status (such as speed, acceleration, and trajectory deviation) also improves the accuracy of fluctuation detection to avoid misjudgment. Finally, closed-loop correction improves the stability of the spray gun's movement, ensuring uniform spraying and consistent thickness. Moreover, the dynamic self-adaptation during the spraying process improves the final coating quality, rapidly evaporating solvents or moisture in the coating and preventing mixing, sagging, or cracking during subsequent primer spraying, thus contributing to improved ceramic coating adhesion and interlayer bonding strength.

[0032] Furthermore, the specific process of real-time monitoring of the fluctuations in the end spray gun based on the built-in driver of the automatic spraying robot is as follows:

[0033] Step 1: Obtain the end spray gun fluctuation parameters of the set spraying cycle, and plot the instantaneous linear velocity and instantaneous angular velocity against time to obtain the corresponding fluctuation curves. The end spray gun fluctuation parameters are read by the built-in driver of the automatic spraying robot, including instantaneous linear velocity, instantaneous angular velocity and driver current. The fluctuation curves include linear velocity curves and angular velocity curves.

[0034] It should be noted that both the linear velocity curve and the angular velocity curve are two-dimensional curves. The horizontal axis of the linear velocity curve represents the time point in the spraying cycle, and the vertical axis represents the instantaneous linear velocity at the corresponding time point. Similarly, the horizontal axis of the angular velocity curve also represents the time point in the spraying cycle, and the vertical axis represents the instantaneous angular velocity at the corresponding time point.

[0035] Step 2: Based on the fluctuation curve and the corresponding spray gun movement speed fluctuation limit parameters, mark the fluctuation exceeding the limit to present the situation of spray gun movement speed fluctuation more intuitively. The fluctuation exceeding the limit mark means that while marking the exceeding segment to divide the period of abnormal spray gun movement speed fluctuation, the time point of the abnormality of spray gun movement speed fluctuation does not meet the fluctuation abnormality range is also marked as the exceeding point. The spray gun movement speed fluctuation limit parameters include the linear velocity fluctuation difference limit range and the angular velocity fluctuation difference limit range.

[0036] It should be explained that the spray gun movement speed fluctuation limit parameter is retrieved and used from the preset database. It is usually set in advance by professional technicians based on experience rules and the requirements of the automated spraying process, and stored in the preset database. Similarly, the fluctuation abnormal range is also retrieved and used from the preset database. It is usually set in advance by professional technicians based on experience rules and the requirements of the automated spraying process, and stored in the preset database.

[0037] In this embodiment, raw data is directly acquired through the built-in driver of the automatic spraying robot, which has strong real-time performance and avoids the delay or insufficient accuracy of external sensors. By collecting three dimensions of parameters—instantaneous linear velocity, instantaneous angular velocity, and driver current—the monitoring of the spray gun's motion status is more comprehensive. The abstract values ​​are presented intuitively in the form of curves, which not only facilitates the identification of fluctuation trends and abnormal locations, but also facilitates comparative analysis between historical cycles and the current cycle to improve trend judgment capabilities. At the same time, by automatically marking "exceeding standard segments" (continuous abnormal intervals) and "exceeding standard points" (discrete abnormal points), the distribution of fluctuation anomalies over time and single-point abrupt changes can be reflected simultaneously, more accurately reflecting the fluctuation of the spray gun's motion.

[0038] It should be added that the specific content of the out-of-range segment marking is as follows: the time period in the linear velocity curve where the instantaneous linear velocity does not fall within the limit range of linear velocity fluctuation difference is marked as the linear velocity fluctuation out-of-range segment; the time period in the angular velocity curve where the instantaneous angular velocity does not fall within the limit range of angular velocity fluctuation difference is marked as the angular velocity fluctuation out-of-range segment.

[0039] like Figure 2The diagram illustrates the process for marking out-of-range points according to an embodiment of the present invention. The specific logic is as follows: Instantaneous linear velocity and instantaneous angular velocity values ​​that do not fall within the corresponding limits for linear velocity and angular velocity fluctuation differences are absolutely quantified to obtain instantaneous linear velocity and instantaneous angular velocity out-of-range values, respectively. The instantaneous linear velocity and instantaneous angular velocity out-of-range values ​​are then compared to their extreme out-of-range limits: If the instantaneous linear velocity out-of-range value at a certain time point within the set spraying cycle is greater than the extreme out-of-range limit, then that time point is marked as a linear velocity out-of-range time point; otherwise, it is not marked. Similarly, if the instantaneous angular velocity out-of-range value at a certain time point within the set spraying cycle is greater than the extreme out-of-range limit, then that time point is marked as an angular velocity out-of-range time point; otherwise, it is not marked. This process helps to visualize the quality of the spray gun's operation, allowing maintenance personnel to quickly determine the area or stage of the problem based on the distribution of out-of-range segments, and provides a data foundation for determining the operational stability of the automatic spraying robot.

[0040] It should also be noted that the specific process for marking out-of-range points is as follows:

[0041] The first step is to absolutely quantify the quantities of instantaneous linear velocity and instantaneous angular velocity that do not fall within the corresponding limits for linear velocity fluctuation and angular velocity fluctuation, respectively, to obtain the instantaneous linear velocity exceeding the limit value and the instantaneous angular velocity exceeding the limit value.

[0042] Specifically, when the instantaneous linear velocity is greater than the maximum value of the linear velocity fluctuation difference limit range, the difference between the instantaneous linear velocity and the maximum value of the linear velocity fluctuation difference limit range is calculated, and then the absolute value is calculated to obtain the instantaneous linear velocity exceeding the limit value. When the instantaneous linear velocity is less than the minimum value of the linear velocity fluctuation difference limit range, the difference between the instantaneous linear velocity and the minimum value of the linear velocity fluctuation difference limit range is calculated, and then the absolute value is calculated to obtain the instantaneous linear velocity exceeding the limit value. Similarly, when the instantaneous angular velocity is greater than the maximum value of the linear velocity fluctuation difference limit range, the difference between the instantaneous angular velocity and the maximum value of the angular velocity fluctuation difference limit range is calculated, and then the absolute value is calculated to obtain the instantaneous angular velocity exceeding the limit value. When the instantaneous angular velocity is less than the minimum value of the linear velocity fluctuation difference limit range, the difference between the instantaneous angular velocity and the minimum value of the angular velocity fluctuation difference limit range is calculated, and then the absolute value is calculated to obtain the instantaneous angular velocity exceeding the limit value.

[0043] The second step is to compare the instantaneous linear velocity exceeding the limit and the instantaneous angular velocity exceeding the limit with the preset extreme exceeding limits respectively: if the instantaneous linear velocity exceeding the limit is greater than the extreme exceeding limit of instantaneous linear velocity at a certain time point in the set spraying cycle, then the time point is marked as the linear velocity exceeding time point, otherwise it is not marked; if the instantaneous angular velocity exceeding the limit is greater than the extreme exceeding limit of instantaneous angular velocity at a certain time point in the set spraying cycle, then the time point is marked as the angular velocity exceeding time point, otherwise it is not marked; the extreme exceeding limits include the extreme exceeding limits of instantaneous linear velocity and the extreme exceeding limits of instantaneous angular velocity.

[0044] Among them, the extreme exceedance limit value represents the maximum tolerable fluctuation limit value of instantaneous linear velocity and instantaneous angular velocity. It is usually set in advance by professional technicians based on historical data and empirical rules, and stored in a preset database.

[0045] In this embodiment, the out-of-range marking mechanism can identify persistent motion anomalies, such as a spray gun movement that significantly deviates from the expected trajectory within a certain period of time. This avoids misjudging occasional minor fluctuations as anomalies, thereby improving the robustness of fluctuation identification and helping to assess the persistence and severity of anomalies. It also provides a more reliable basis for subsequent correction strategies (such as speed reduction or path replanning). Furthermore, it can visualize the spray gun's operating quality, allowing maintenance personnel to quickly determine which trajectory area or action stage the problem occurs in by observing the out-of-range distribution. It can capture severe fluctuations in a short period of time (such as shaking, impact, and vibration peaks), avoiding missing sudden fault signs. Moreover, by comparing with extreme limit values, it distinguishes between "acceptable deviations" and "hazardous mutations," achieving more accurate anomaly classification.

[0046] like Figure 3The diagram shown is a flowchart illustrating the preliminary judgment of spray gun motion fluctuations provided in an embodiment of the present invention. The specific logic is as follows: Statistics are performed on the excessive linear velocity fluctuation segments, excessive angular velocity fluctuation segments, excessive linear velocity time points, and excessive angular velocity time points to obtain a spray gun motion speed fluctuation exceeding index. Based on this index, a comprehensive value for excessive linear velocity fluctuation is obtained. Simultaneously, based on the index, a comprehensive value for excessive angular velocity fluctuation is obtained. Then, based on the comprehensive values ​​for excessive linear velocity and angular velocity fluctuations, a preliminary judgment value for spray gun motion fluctuations is obtained. Finally, the preliminary judgment value for spray gun motion fluctuations is compared with the extracted spray gun motion fluctuation threshold. The comparison process is as follows: If the initial judgment value of the spray gun movement fluctuation is greater than the spray gun movement fluctuation threshold, the driver current is introduced for auxiliary verification and judgment. At the same time, robot spraying prevention measures are activated to intervene in advance in case of possible abnormal fluctuations in robot movement speed. If the initial judgment value of the spray gun movement fluctuation is not greater than the spray gun movement fluctuation threshold, the next spraying cycle is monitored, and the fluctuation trend change is analyzed to detect abnormal fluctuations in robot movement speed in a timely manner, and thus intervene in advance. Through the above process, not only is predictive maintenance of the automatic spraying robot achieved, but the impact of robot movement speed fluctuations on the quality of ceramic coatings is also reduced.

[0047] Furthermore, the specific steps for making a preliminary judgment on the spray gun's motion fluctuations are as follows:

[0048] S1. Statistical analysis is performed on the linear velocity fluctuation exceeding the standard segment, the angular velocity fluctuation exceeding the standard segment, the linear velocity exceeding the standard time point, and the angular velocity exceeding the standard time point to obtain the spray gun motion speed fluctuation exceeding the standard index. The spray gun motion speed fluctuation exceeding the standard index includes the length of the linear velocity fluctuation exceeding the standard segment, the length of the angular velocity fluctuation exceeding the standard segment, the number of linear velocity exceeding the standard time point, and the number of angular velocity exceeding the standard time point.

[0049] S2. Based on the length of the linear velocity fluctuation exceeding the standard segment and the number of time points when the linear velocity exceeds the standard, a comprehensive value for linear velocity fluctuation exceeding the standard is obtained. Based on the length of the angular velocity fluctuation exceeding the standard segment and the number of time points when the angular velocity exceeds the standard, a comprehensive value for angular velocity fluctuation exceeding the standard is obtained. Based on the comprehensive value for linear velocity fluctuation exceeding the standard and the comprehensive value for angular velocity fluctuation exceeding the standard, a preliminary judgment value for spray gun motion fluctuation is obtained.

[0050] It should be added that after normalizing the length of the linear velocity fluctuation exceeding the standard and the number of time points where the linear velocity exceeds the standard, the comprehensive value X of the linear velocity fluctuation exceeding the standard is obtained by weighted fusion with the set comprehensive quantification factor of linear velocity. The specific expression is as follows:

[0051] ;

[0052] Where x1 represents the length of the linear velocity fluctuation exceeding the standard, x2 represents the number of time points when the linear velocity exceeds the standard, a represents the linear velocity exceeding the standard segment factor, b represents the linear velocity exceeding the standard point factor, and the linear velocity comprehensive quantification factor includes the linear velocity exceeding the standard segment factor and the linear velocity exceeding the standard point factor, which are extracted from the preset database and preset by professional technicians based on the influence degree of the linear velocity fluctuation exceeding the standard comprehensive value according to the length of the linear velocity fluctuation exceeding the standard segment and the number of time points when the linear velocity exceeds the standard.

[0053] It should be added that after normalizing the length of the angular velocity fluctuation exceeding the standard and the number of time points of angular velocity exceeding the standard, the comprehensive value Y of angular velocity fluctuation exceeding the standard is obtained by weighted fusion with the set comprehensive angular velocity quantization factor. The specific expression is as follows:

[0054] ;

[0055] Where y1 represents the length of the segment exceeding the angular velocity fluctuation limit, y2 represents the number of time points when the angular velocity exceeds the limit, c represents the angular velocity exceeding the limit segment factor, and d represents the angular velocity exceeding the limit point factor. The comprehensive angular velocity quantification factor includes the angular velocity exceeding the limit segment factor and the angular velocity exceeding the limit point factor, which are extracted from a preset database and preset by professional technicians based on the influence degree of the comprehensive value of angular velocity fluctuation exceeding the limit according to the length of the angular velocity fluctuation exceeding the limit segment and the number of time points when the angular velocity exceeds the limit.

[0056] It should be added that the specific expression for the preliminary judgment value Z of the spray gun motion fluctuation is as follows:

[0057]

[0058] In the formula, φ represents the weight of linear velocity fluctuation, and ρ represents the weight of angular velocity fluctuation. The weights of linear velocity fluctuation and angular velocity fluctuation belong to the weights of spray gun fluctuation, which are extracted from the preset database.

[0059] It needs to be further added that the spray gun fluctuation influence weight is used to represent the degree of influence of the comprehensive value of linear velocity fluctuation exceeding the standard and the comprehensive value of angular velocity fluctuation exceeding the standard on the preliminary judgment value of spray gun motion fluctuation. The spray gun fluctuation influence weight is input into the spray gun motion fluctuation weight mapping model after training, and the corresponding spray gun fluctuation influence weight is output. The spray gun motion fluctuation weight mapping model is used to fit the mapping relationship between the spray gun fluctuation influence weight and the comprehensive value of linear velocity fluctuation exceeding the standard and the comprehensive value of angular velocity fluctuation exceeding the standard. The spray gun motion fluctuation weight mapping model is obtained by professional technicians through spray gun motion fluctuation training data. The spray gun motion fluctuation training data includes the spray gun motion speed fluctuation exceeding the standard index obtained from the instantaneous linear velocity and instantaneous angular velocity in the historical time period data, the comprehensive value of linear velocity fluctuation exceeding the standard and the comprehensive value of angular velocity fluctuation exceeding the standard obtained from the spray gun motion speed fluctuation exceeding the standard index, and the corresponding spray gun fluctuation influence weight set by professional technicians based on empirical rules.

[0060] S3. The initial judgment value of the spray gun movement fluctuation is compared with the spray gun movement fluctuation threshold extracted from the preset database. The spray gun movement fluctuation threshold represents the maximum limit for the initial judgment of abnormal spray gun movement fluctuation. It is extracted from the preset database and is generally set by professional technicians based on experience rules and stored in the preset database in advance.

[0061] S31, if the initial judgment value of the spray gun movement fluctuation is greater than the spray gun movement fluctuation threshold, the driver current is introduced for auxiliary verification and judgment, and at the same time, robot spraying prevention measures are activated to intervene in advance in case of possible abnormal fluctuations in robot movement speed.

[0062] S32, if the initial judgment value of the spray gun movement fluctuation is not greater than the spray gun movement fluctuation threshold, then continue to monitor the next spraying cycle, and at the same time perform fluctuation trend change analysis to detect abnormal robot movement speed fluctuation in a timely manner, and then intervene in advance to reduce the impact of abnormal robot movement speed fluctuation on the ceramic coating spraying of prebaked anode.

[0063] In this embodiment, the spray gun motion fluctuation is quantified into statistical indicators to form a standardized monitoring method. It considers both the "duration of exceeding the standard" and the "number of sudden exceeding the standard," avoiding missed or false judgments caused by relying on a single parameter. Furthermore, by fusing segment length and the number of time points, a comprehensive value of linear velocity and angular velocity is obtained, taking into account both the continuity and frequency of the fluctuation, forming a preliminary judgment value for spray gun motion fluctuation, making anomaly judgment more objective and accurate. Secondary verification is performed using the driver current, avoiding false alarms caused by relying solely on speed data. This auxiliary verification can distinguish between sensor jitter and actual mechanical and drive anomalies, improving accuracy. Additionally, trend analysis enables predictive maintenance, allowing for early intervention before anomalies exceed the standard, reducing the impact of robot motion speed fluctuations on the ceramic coating quality.

[0064] Furthermore, the specific process for introducing driver current for auxiliary verification and judgment is as follows:

[0065] The driver current is matched with a pre-set current fluctuation range, which is preset by a professional technician and stored in a pre-defined database.

[0066] If the driver current falls within the current fluctuation range, the robot spraying prevention range is obtained by mapping the difference between the initial judgment value of the spray gun motion fluctuation and the spray gun motion fluctuation threshold. Corresponding robot spraying prevention measures are then taken based on the robot spraying prevention range.

[0067] Specifically, the difference between the initial judgment value of the spray gun motion fluctuation and the spray gun motion fluctuation threshold is recorded as the spray gun fluctuation difference value. The spray gun fluctuation difference value is input into the trained spray prevention mapping table, and the corresponding robot spray prevention amplitude is output. The spray prevention mapping table is used to reflect the mapping relationship between the spray gun fluctuation difference value and the robot spray prevention amplitude. The spray prevention mapping table is trained using spray prevention training data, which includes the spray gun fluctuation difference values ​​obtained in historical time periods and the corresponding robot spray prevention amplitude set by professional technicians based on experience rules.

[0068] If the driver current is not within the current fluctuation range, robot painting correction is performed to reduce the probability of abnormal fluctuations in the movement speed of the automatic painting robot.

[0069] In this embodiment, based on the initial judgment of motion fluctuations, current is introduced as a physical quantity for verification, avoiding false alarms caused by relying solely on speed and angular velocity data. Furthermore, the current signal directly reflects load changes and servo system status, which can more realistically reflect abnormal robot mechanical motion. If the driver current is within the fluctuation range, it indicates that the electrical status is normal, and the motion fluctuation may be a mild or acceptable disturbance. The "spraying prevention amplitude" is obtained based on the difference between the initial judgment value and the threshold, realizing graded response. This indicates that the motion abnormality is accompanied by current abnormality, which may involve serious situations such as mechanical jamming, overload, and servo jitter. At the same time, the system immediately performs spraying correction, which is not only preventative but also effectively reduces the probability of abnormal robot motion speed fluctuations. Through the rapid intervention of correction measures, serious fluctuations are prevented from further affecting the ceramic coating quality or causing equipment damage.

[0070] Furthermore, the specific details of the preventative measures for robotic spraying are as follows:

[0071] First, the robot correction frequency adjustment value is obtained based on the offset projection of the driver current and the current fluctuation range.

[0072] It should be added that the difference between the driver current and the maximum or minimum value of the current fluctuation range is compared with the maximum or minimum value of the corresponding current fluctuation range to obtain the corresponding current offset. The current offset is then input into the robot correction projection sequence, and the corresponding robot correction frequency adjustment value is obtained by projection. The robot correction projection sequence is pre-trained based on robot correction training data, which includes current offsets obtained from historical time periods and robot correction frequency adjustment values ​​pre-set by professional technicians according to experience rules.

[0073] Next, the robot correction frequency is compensated based on the robot correction frequency adjustment value to obtain the optimized robot correction frequency. Specifically, the robot correction frequency adjustment value and the robot correction frequency are multiplied to obtain the optimized robot correction frequency.

[0074] Finally, the fluctuations in the speed of the automated painting robot were corrected by optimizing the robot correction frequency.

[0075] In this embodiment, the current, as a sensitive parameter of the robot's load and operating status, can more directly reflect the actual intensity of abnormal spray gun movement, making the compensation basis more accurate. Furthermore, the correction frequency is dynamically adjusted through mathematical compensation calculations to match the degree of abnormality, rather than using a fixed value. The optimized correction frequency can be automatically updated with changes in working conditions, improving the robustness of the automated process control system. Moreover, when speed fluctuations occur, they are suppressed through real-time frequency adjustment, ensuring the smoothness of the spray gun's movement trajectory. This improves the accuracy and stability of speed control during the spraying process, thereby enhancing the uniformity and adhesion of the ceramic coating thickness. It also avoids spraying defects or rework caused by excessive fluctuations, reducing energy consumption and material waste.

[0076] Furthermore, the specific details of the robotic painting correction are as follows:

[0077] The robot correction frequency optimization value is obtained by mapping the offset between the driver current and the current fluctuation range.

[0078] It should be noted that the difference between the driver current and the maximum or minimum value of the current fluctuation range is recorded as the ratio of the difference to the maximum or minimum value of the corresponding current fluctuation range. The result of this ratio calculation is the drive current fluctuation amount. The drive current fluctuation amount is input into the robot correction mapping set, and the corresponding robot correction frequency optimization value is obtained by mapping. The robot correction mapping set is pre-trained based on robot adjustment training data. The robot adjustment training data includes the drive current fluctuation amount obtained from historical time periods, as well as the robot correction frequency optimization value pre-set by professional technicians according to experience rules.

[0079] The robot's initial step size is compensated by the robot's corrected frequency optimization value. This means that the adjusted step size is obtained by multiplying the robot's corrected frequency optimization value with the robot's initial step size.

[0080] An automated spraying robot applies a ceramic coating to the prebaked anode carbon block by adjusting the step length.

[0081] In this embodiment, the current offset is used as a feedback signal to directly reflect the load state and motion abnormality of the automatic spraying robot. Furthermore, by mapping, an optimized correction frequency value is obtained, enabling adaptive adjustment of the spraying correction. This avoids the static nature of single fixed parameter control, improves the real-time nature and targeting of the correction strategy, and makes the correction more consistent with the actual operation of the spray gun. The correction frequency is converted into step size compensation, achieving precise correction from the "frequency level" to the "displacement level." Step size compensation directly affects the accuracy of the spraying trajectory, making the spray gun trajectory more stable. Dynamic step size adjustment also avoids sudden speed changes or trajectory drift during spraying, improving the smoothness of trajectory control. Spraying under the corrected step size helps reduce the impact of motion fluctuations on the uniformity of the coating thickness, ensuring a denser and more uniform ceramic coating, and improving the adhesion and oxidation resistance of the ceramic coating.

[0082] As a further embodiment, the specific process for analyzing fluctuation trends is as follows:

[0083] S321, quantify the percentage change of the spray gun movement speed fluctuation exceeding the standard index and the spray gun movement speed fluctuation exceeding the standard index in the next spraying cycle, and obtain the corresponding fluctuation change rate. The fluctuation change rate includes the change rate of the length of the linear velocity fluctuation exceeding the standard segment, the change rate of the length of the angular velocity fluctuation exceeding the standard segment, the change rate of the number of time points of linear velocity exceeding the standard, and the change rate of the number of time points of angular velocity exceeding the standard.

[0084] Specifically, the ratio of the spray gun movement speed fluctuation exceeding the standard index to the spray gun movement speed fluctuation exceeding the standard index in the next spraying cycle is calculated to obtain the corresponding fluctuation change rate. The fluctuation change rate includes the change rate of the length of the linear velocity fluctuation exceeding the standard segment, the change rate of the length of the angular velocity fluctuation exceeding the standard segment, the change rate of the number of time points of linear velocity exceeding the standard, and the change rate of the number of time points of angular velocity exceeding the standard.

[0085] S322, comprehensively quantify the rate of change of fluctuation to obtain the total rate of change value, and compare the total rate of change value with the extracted rate of change judgment value. The rate of change judgment value is extracted from a preset database and is specifically set in advance by professional technicians based on experience rules.

[0086] If the total rate of change is greater than the rate of change judgment value, the robot spraying prevention measures are activated. The corresponding spraying prevention range is obtained by mapping the difference between the total rate of change and the rate of change judgment value. The robot correction frequency is compensated according to the spraying prevention range by multiplying the spraying prevention range and the robot correction frequency to obtain the adjusted robot correction frequency. The fluctuation of the automatic spraying robot speed is corrected by adjusting the robot correction frequency.

[0087] It should be explained that the difference between the total rate of change and the rate of change determination value is called the rate of change difference. The rate of change difference is input into the rate of change mapping dataset to match the corresponding spraying prevention range. The rate of change mapping dataset is obtained after training on the rate of change mapping training data. It is used to fit the mapping relationship between the rate of change difference and the spraying prevention range. The rate of change mapping training data includes the rate of change difference obtained from historical time periods, as well as the spraying prevention range set by professional technicians based on experience rules.

[0088] If the total rate of change is not greater than the rate of change judgment value, then continue to monitor the next spraying cycle and conduct fluctuation trend analysis.

[0089] In this embodiment, the fluctuation indicators of different spraying cycles are converted into rates of change, which can more directly reflect the trend of the spray gun's motion fluctuations rather than just the static state. At the same time, through multi-dimensional indicators such as the rate of change of linear velocity segment length, the rate of change of angular velocity segment length, and the rate of change of the number of time points exceeding the standard, the fluctuation trend is comprehensively characterized, enabling the system to have an "early warning capability" for potential anomalies. Risk signals can be captured before the fluctuations become serious. In addition, by quantifying the comprehensive value, a comparable numerical standard can be formed, which is convenient for subsequent comparison with the judgment value. The spraying prevention range is obtained by mapping the difference, realizing graded intervention "according to trend intensity". Furthermore, by dynamically adjusting the robot's operating state through compensation correction frequency, fluctuations are corrected in advance, ensuring spraying stability and coating uniformity.

[0090] Further analysis of fluctuation trends is conducted, which also includes:

[0091] If the total value of the rate of change is within the range of the rate of change fluctuation limit, then the spraying cycle is marked as the maximum limit spraying cycle. The spray gun movement speed fluctuation exceeding the standard index of the preset number of spraying cycles is quantified by ratio with the spray gun movement speed fluctuation exceeding the standard index of the maximum limit spraying cycle, and the fluctuation rate is comprehensively quantified to obtain the corresponding total value of the rate of change.

[0092] It should be explained that the rate of change fluctuation limit range represents the maximum range of fluctuation rate that the system can accept. It is obtained from the preset database and is usually preset and stored in the preset database by professional technicians for later use.

[0093] The total rate of change is compared with the rate of change judgment value to determine whether to conduct a fluctuation trend analysis for the next spraying cycle. If not, robot spraying prevention measures are initiated, and the fluctuation of the automatic spraying robot speed is corrected based on adjusting the robot correction frequency.

[0094] It should be noted that the steps after obtaining the total rate of change are the same as those after obtaining the total rate of change through the aforementioned fluctuation trend analysis.

[0095] In this embodiment, the concept of "maximum limiting spraying cycle" is introduced, which can be used to benchmark the extreme fluctuations in the spraying process. Using this cycle as a benchmark helps to measure the difference between subsequent spraying cycles and the extreme state, facilitating multi-cycle comparative analysis and improving the continuity and scientific nature of trend judgment. At the same time, through ratio processing, it can not only reflect the fluctuations within a single cycle, but also reflect the relative change trend across cycles, eliminating the interference of absolute numerical differences between different cycles, making the results more comparable and stable. Moreover, when the trend change exceeds the reasonable range, preventive measures are immediately taken to correct the spray gun movement fluctuations. Based on the correction method of adjusting the correction frequency, the spray gun speed fluctuations can be precisely controlled to prevent the abnormal movement speed of the automatic spraying robot from further deteriorating, thereby improving the stability and reliability of robot operation.

[0096] The above embodiments can be implemented, in whole or in part, by software, hardware (such as circuits), firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. A computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, all or part of the flow or function according to the embodiments of the present invention is generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. Computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., infrared, wireless, microwave, etc.) means. A computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that includes one or more sets of available media. Available media can be magnetic media (e.g., floppy disks, hard disks, magnetic tapes), optical media (e.g., DVDs), or semiconductor media. Semiconductor media can be solid-state drives.

[0097] It should be understood that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. A and B can be singular or plural. Additionally, the character " / " in this article generally indicates an "or" relationship between the preceding and following related objects, but it can also represent an "and / or" relationship. Please refer to the context for a more accurate understanding.

[0098] In this invention, "at least one" means one or more, and "more than one" means two or more. "At least one of the following" or similar expressions refer to any combination of these items, including any combination of a single item or a plurality of items. For example, at least one of a, b, or c can represent: a, b, c, ab, ac, bc, or abc, where a, b, and c can be a single item or multiple items.

[0099] It should be understood that, in various embodiments of the present invention, the order of the above-mentioned process numbers does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0100] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0101] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the devices, apparatuses, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0102] In the embodiments provided by this invention, it should be understood that the disclosed devices, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another device, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between devices or units may be electrical, mechanical, or other forms.

[0103] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0104] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0105] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0106] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An automated process control system for ceramic coatings with prebaked anode anti-oxidation function, characterized in that, It includes a pre-treatment module for prebaked anode spraying, a module for monitoring spraying fluctuations, a module for correcting and optimizing spraying fluctuations, and a post-treatment module for spraying: The prebaked anode spraying pretreatment module is used to automatically transport the prebaked anode carbon block on a plate chain to the dust removal chamber for dust removal, and then automatically transport the prebaked anode carbon block to the spraying station for ceramic coating topcoat spraying, and spray the prebaked anode carbon block by an automatic spraying robot. The spraying fluctuation monitoring module is used to monitor the fluctuation of the end spray gun in real time according to the built-in driver of the automatic spraying robot, make a preliminary judgment on the spray gun movement fluctuation to initially determine the probability of the spray gun having fluctuation, and determine whether to perform spray gun movement auxiliary judgment to verify whether there is a fluctuation in the spray gun movement. The specific steps for making a preliminary judgment on the motion fluctuation of the spray gun are as follows: The excessive linear velocity fluctuations, excessive angular velocity fluctuations, excessive linear velocity time points, and excessive angular velocity time points are statistically analyzed to obtain the excessive spray gun movement speed index. The excessive spray gun movement speed index includes the length of the excessive linear velocity fluctuation segment, the length of the excessive angular velocity fluctuation segment, the number of excessive linear velocity time points, and the number of excessive angular velocity time points. The comprehensive value of linear velocity fluctuation exceeding the standard is obtained based on the length of the linear velocity fluctuation exceeding the standard and the number of time points when the linear velocity exceeds the standard. The comprehensive value of angular velocity fluctuation exceeding the standard is obtained based on the length of the angular velocity fluctuation exceeding the standard and the number of time points when the angular velocity exceeds the standard. The preliminary judgment value of spray gun motion fluctuation is obtained based on the comprehensive value of linear velocity fluctuation exceeding the standard and the comprehensive value of angular velocity fluctuation exceeding the standard. The preliminary judgment value of spray gun motion fluctuation is compared with the extracted spray gun motion fluctuation threshold: If the initial judgment value of the spray gun movement fluctuation is greater than the spray gun movement fluctuation threshold, the driver current is introduced for auxiliary verification and judgment, and at the same time, robot spraying prevention measures are activated to intervene in the possible abnormal fluctuation of robot movement speed in advance. If the initial judgment value of the spray gun movement fluctuation is not greater than the spray gun movement fluctuation threshold, then continue to monitor the next spraying cycle, and at the same time perform fluctuation trend change analysis to detect abnormal fluctuations in robot movement speed in a timely manner, and then intervene in advance. The spraying fluctuation correction and optimization module is used to determine whether to perform robot spraying correction based on the result of spray gun motion auxiliary judgment in order to improve the stability of the end spray gun motion of the spraying robot. The specific process of real-time monitoring of the fluctuation of the end spray gun based on the built-in driver of the automatic spraying robot is as follows: The end spray gun fluctuation parameters of the set spraying cycle are obtained, and the instantaneous linear velocity and instantaneous angular velocity are plotted against time to obtain the corresponding fluctuation curve. The end spray gun fluctuation parameters are read by the built-in driver of the automatic spraying robot, including instantaneous linear velocity, instantaneous angular velocity and driver current. The fluctuation curve includes a linear velocity curve and an angular velocity curve. Based on the fluctuation curve and the corresponding spray gun movement speed fluctuation limit parameters, fluctuation exceeding the limit is marked to present the situation of spray gun movement speed fluctuation more intuitively. The fluctuation exceeding the limit mark means that while marking the exceeding segment for dividing the period of abnormal spray gun movement speed fluctuation, the time point of the abnormality of spray gun movement speed fluctuation does not meet the fluctuation abnormality range is also marked as the exceeding point. The spray gun movement speed fluctuation limit parameters include the linear velocity fluctuation difference limit range and the angular velocity fluctuation difference limit range. The specific details of the out-of-range segment markers are as follows: The time period in the linear velocity curve where the instantaneous linear velocity does not fall within the limit range of linear velocity fluctuation difference is marked as the linear velocity fluctuation exceeding the limit segment. The time period in the angular velocity curve where the instantaneous angular velocity does not fall within the limit range of angular velocity fluctuation difference is marked as the angular velocity fluctuation exceeding the limit segment; The specific process for marking out-of-range points is as follows: The quantities of instantaneous linear velocity and instantaneous angular velocity that do not fall within the corresponding limits for linear velocity fluctuation difference and angular velocity fluctuation difference are absolutely quantified to obtain the instantaneous linear velocity exceeding the limit value and the instantaneous angular velocity exceeding the limit value, respectively. The instantaneous linear velocity exceeding the limit and the instantaneous angular velocity exceeding the limit are compared with the preset extreme exceeding limit values ​​respectively: If the instantaneous linear velocity exceeds the extreme limit of instantaneous linear velocity at a certain point in the set spraying cycle, then that point in time is marked as the linear velocity exceeding the limit; otherwise, it is not marked. If the instantaneous angular velocity exceeds the extreme limit value at a certain point in the set spraying cycle, then that point in time is marked as the point where the angular velocity exceeds the limit; otherwise, it is not marked. The extreme exceedance limits include extreme exceedance limits for instantaneous linear velocity and extreme exceedance limits for instantaneous angular velocity; The post-coating processing module is used to transport the prebaked anode carbon block after spraying to the flash-drying area. After flash-drying, the prebaked anode carbon block is transported to the next spraying station for the primer spraying of the ceramic coating.

2. The automated process control system for ceramic coatings with prebaked anode anti-oxidation function according to claim 1, characterized in that, The specific process for introducing driver current for auxiliary verification and judgment is as follows: Match the driver current to the set current fluctuation range: If the driver current is within the current fluctuation range, the robot spraying prevention range is obtained by mapping the difference between the initial judgment value of the spray gun motion fluctuation and the spray gun motion fluctuation threshold, and corresponding robot spraying prevention measures are taken based on the robot spraying prevention range. If the driver current is not within the current fluctuation range, robot painting correction is performed to reduce the probability of abnormal fluctuations in the movement speed of the automatic painting robot.

3. The automated process control system for ceramic coatings with prebaked anode anti-oxidation function according to claim 2, characterized in that, The specific details of the robot spraying preventative measures are as follows: The robot's corrected frequency adjustment value is obtained by projecting the offset of the driver current and the current fluctuation range. The robot correction frequency is compensated based on the robot correction frequency adjustment value to obtain the optimized robot correction frequency. The fluctuations in the speed of the automated painting robot are corrected by optimizing the robot correction frequency.

4. The automated process control system for ceramic coatings with prebaked anode anti-oxidation function according to claim 2, characterized in that, The specific details of the robotic painting correction are as follows: The robot correction frequency optimization value is obtained by mapping the offset of the driver current and the current fluctuation range. The robot's initial step size is then compensated using the robot correction frequency optimization value to obtain the adjustment step size. An automated spraying robot applies a ceramic coating to the prebaked anode carbon block by adjusting the step length.

5. The automated process control system for ceramic coatings with prebaked anode anti-oxidation function according to claim 1, characterized in that, The specific process for analyzing fluctuation trends is as follows: The percentage change of the spray gun movement speed fluctuation exceeding the standard index and the spray gun movement speed fluctuation exceeding the standard index in the next spraying cycle are quantified to obtain the corresponding fluctuation change rate. The fluctuation change rate includes the change rate of the length of the linear velocity fluctuation exceeding the standard segment, the change rate of the length of the angular velocity fluctuation exceeding the standard segment, the change rate of the number of time points of linear velocity exceeding the standard, and the change rate of the number of time points of angular velocity exceeding the standard. The total rate of change is obtained by comprehensively quantifying the rate of change, and then compared with the extracted rate of change judgment value: If the total rate of change is greater than the rate of change judgment value, the robot spraying prevention measures are activated, and the corresponding spraying prevention range is obtained by mapping the difference between the total rate of change and the rate of change judgment value. The robot correction frequency is compensated according to the spraying prevention range to obtain the adjusted robot correction frequency. The fluctuation of the automatic spraying robot speed is corrected by adjusting the robot correction frequency. If the total rate of change is not greater than the rate of change judgment value, then continue to monitor the next spraying cycle and conduct fluctuation trend analysis.

6. The automated process control system for ceramic coatings with prebaked anode anti-oxidation function according to claim 5, characterized in that, The analysis of fluctuation trend changes also includes: If the total value of the rate of change is within the range of the rate of change fluctuation limit, then the spraying cycle is marked as the maximum limit spraying cycle. The spray gun movement speed fluctuation exceeding the standard index of the preset number of spraying cycles is quantified by ratio with the spray gun movement speed fluctuation exceeding the standard index of the maximum limit spraying cycle, and the fluctuation rate is comprehensively quantified to obtain the corresponding total value of the rate of change. The total rate of change is compared with the rate of change judgment value to determine whether to conduct a fluctuation trend analysis for the next spraying cycle. If not, robot spraying prevention measures are initiated, and the fluctuation of the automatic spraying robot speed is corrected based on adjusting the robot correction frequency.

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