A method and apparatus for repairing defects in the remanufacturing of automotive parts

Abstract

This invention provides a method and apparatus for repairing defects in the remanufacturing of automotive parts. The apparatus comprises a placement unit, a moving unit, an angle adjustment mechanism, and a repair spraying unit. The placement unit includes a base with a placement plate on top. A driven turntable is rotatably mounted on the placement plate, and automotive frame parts are placed on the driven turntable. A drive motor is mounted on the top of the base, and the output shaft of the drive motor is fixedly connected to the bottom of the driven turntable. The placement unit is used to place the automotive frame parts on the driven turntable and rotates to adjust the spraying repair direction as needed. The method and apparatus provided by this invention are used in the remanufacturing process of automotive frame parts for automated scanning, detection, and spraying repair of defects such as surface cracks, paint peeling, missing parts, and rust.

Description

Technical Field

[0001] This invention belongs to the field of automotive parts repair technology, and particularly relates to a method and apparatus for repairing defects in the remanufacturing of automotive parts. Background Technology

[0002] Remanufacturing of automotive parts is a core technology for achieving green and circular development of the automotive industry, reducing parts replacement costs, and saving production resources. As the core load-bearing structural components of automobiles, automotive frame parts are prone to defects such as surface corrosion, coating peeling, minor defects, and micro-cracks after long-term use, and need to be repaired and processed to achieve remanufacturing and reuse.

[0003] Current equipment for repairing defects in the remanufacturing of automotive frame components has technical shortcomings: Firstly, existing repair equipment mostly adopts manual positioning and manual spraying repair methods. The error of manually observing the defect location is large, and it is impossible to accurately identify small hidden defects. The repair accuracy is low, and problems such as missed repair, over-repair, and misaligned repair are very easy to occur, resulting in a low qualification rate of remanufacturing of parts. Secondly, the existing equipment has a rigid structure, and the angle of the parts is fixed after placement. The position of the repair mechanism cannot be flexibly adjusted, making it difficult to adapt to the repair of complex structural defects of frame parts with multiple curved surfaces and corners, resulting in poor operational adaptability.

[0004] Therefore, it is necessary to provide a new method and apparatus for repairing defects in the remanufacturing of automotive parts to solve the above-mentioned technical problems. Summary of the Invention

[0005] The technical problem solved by this invention is to provide a method and apparatus for repairing defects in automotive parts during the remanufacturing of scrap automotive frame parts, which is used for automated scanning detection and spraying repair of defects such as cracks, paint peeling, defects, and rust on the surface of the parts.

[0006] To solve the above-mentioned technical problems, the present invention provides a method and apparatus for repairing defects in the remanufacturing of automotive parts, comprising: a placement unit, a moving unit, an angle adjustment mechanism, and a repair spraying unit. The placement unit includes a base, a placement plate on top of the base, a driven turntable rotatably mounted on the placement plate, automotive frame parts placed on the driven turntable, and a drive motor mounted on the top of the base. The output shaft of the drive motor is fixedly connected to the bottom of the driven turntable. The placement unit is used to place automotive frame parts on a driven turntable and rotate the spraying and repair direction as needed.

[0007] As a further embodiment of the present invention, the top of the base is provided with a motor mounting slot, the drive motor is fixedly mounted on the bottom inner wall of the motor mounting slot, and four support blocks arranged in a rectangular array are fixedly mounted on the top of the base, the top of the support blocks being fixedly connected to the bottom of the placement plate.

[0008] As a further embodiment of the present invention, the mobile unit is mounted on the placement unit, and the mobile unit includes two rectangular supports, both of which are fixedly mounted on the top of the placement plate; the mobile unit also includes a rectangular mounting box, a second drive motor, a first bevel gear, a second bevel gear, a rotating shaft, a gear, a rectangular moving strip, a driven rack, and a rectangular mounting slot; the rectangular mounting box is disposed between the two rectangular supports, and the sides of the two rectangular supports that are close to each other are fixedly connected to the rectangular mounting box; the second drive motor is fixedly mounted on the top of the rectangular mounting box, and the output shaft of the second drive motor extends into the rectangular mounting box; A first bevel gear is fixedly mounted on the output shaft of a second drive motor, and is located within a rectangular mounting box. A second bevel gear is also located within the rectangular mounting box, meshing with the first bevel gear. A rotating shaft is rotatably mounted within the rectangular mounting box, with one end fixedly connected to the second bevel gear. A toothed gear is fixedly sleeved on the rotating shaft. A rectangular moving strip is located within the rectangular mounting box, with both ends of the strip penetrating the box. A rectangular mounting slot is formed on the bottom inner wall of the rectangular moving strip. A driven rack is fixedly mounted on the top inner wall of the rectangular mounting slot, meshing with the toothed gear. This moving unit is used for the subsequent left and right movement of the angle adjustment mechanism.

[0009] As a further embodiment of the present invention, the angle adjustment mechanism is movably mounted on the mobile unit. The angle adjustment mechanism includes a telescopic cylinder, which is fixedly mounted on the top of the rectangular moving bar. The angle adjustment mechanism also includes a limiting slider, a first hinge rod, a first hinge block, a high-definition industrial camera, a second hinge block, a second hinge rod, the limiting connection port, and a wire. The limiting slider is fixedly mounted on the output shaft of the telescopic cylinder and slidably mounted on the rectangular moving bar. The first hinge rod is hinged to the bottom of the limiting slider. The first hinge block is hinged to the bottom end of the first hinge rod. The industrial camera is positioned below the rectangular moving bar. Hinge block one is fixedly mounted on the high-definition industrial camera; hinge block two is also fixedly mounted on the high-definition industrial camera; hinge rod two is hinged to hinge block two, with its top end fixedly connected to the bottom of the rectangular moving bar; a limiting connection port is located at the top of the rectangular moving bar, and a limiting slider is slidably connected to the limiting connection port; the wire is electrically connected to the high-definition industrial camera; the angle adjustment mechanism is used for scanning and inspection, scanning and observing the location of parts requiring repair on automotive frame components, and can adjust the shooting angle of the high-definition industrial camera as needed.

[0010] As a further embodiment of the present invention, the repair spraying unit includes a powder storage tank, which is fixedly installed on the top of a rectangular mounting box; the repair spraying unit also includes a spraying hose and a repair spray gun; the spraying hose is fixedly connected to the left side of the powder storage tank; the repair spray gun is detachably connected to the end of the spraying hose away from the powder storage tank; the repair spray gun is model AZ3; the repair spraying unit is mounted on a mobile unit and is used for powder spraying repair of defective parts.

[0011] The present invention also provides a method for repairing defects in the remanufacturing of automotive parts, using the aforementioned automotive parts remanufacturing defect repair device, including a control screen and a fully closed-loop intelligent electronic control defect repair system disposed within the control screen, wherein the control screen is fixedly installed on the outside of a corresponding rectangular bracket; The fully closed-loop intelligent electronic control defect repair system mainly includes: The image acquisition and transmission module relies on a high-definition industrial camera to complete the real-time acquisition of full-area optical images of the surface of automotive frame components. An intelligent defect identification and analysis module is used to receive digital image data output by an image acquisition and transmission module. A multi-dimensional positioning and control module is used to receive defect quantification parameters and coordinate data output by the intelligent defect identification and analysis module; An adaptive spraying control module, wherein the adaptive spraying control module uses the defect area and depth level parameters output by the defect identification and analysis module; The precision servo drive module serves as the core of the closed-loop control for the power execution of the entire device, and receives action commands from various control modules. The human-machine interaction control module is used to establish a two-way interaction channel between the equipment and the human, and is carried on the control screen to realize functions such as manual configuration of equipment parameters, switching between automatic / manual operation modes, real-time visual display of equipment operating status, defect data statistics, and repair progress monitoring. The fault self-diagnosis and protection module can sample and monitor the operating parameters of various electrical components and actuators of the equipment in real time throughout the entire process, such as current, voltage, displacement, and signal continuity. As a further embodiment of the present invention, the image acquisition and transmission module is the system data input port, which is core-connected to a high-definition industrial camera and wires. It relies on the photoelectric conversion principle to realize the accurate conversion of optical images into digital electrical signals, and is equipped with differential transmission anti-interference electrical control logic to eliminate image distortion caused by electromagnetic interference in the industrial environment.

[0012] After the equipment is powered on, the PLC main control chip outputs a constant 5V low-voltage regulated power supply signal, which continuously powers the high-definition industrial camera via a wire. Simultaneously, it outputs a 30Hz synchronous trigger pulse to control the camera to acquire full-area images of the component surface frame by frame at a fixed frame rate. The camera's internal CMOS image sensor captures optical images, converting the light signal into an analog electrical signal. This signal is then quantized into a 0-255 grayscale digital image signal by the internal AD conversion module and transmitted in real-time to the system's high-speed computing chip via differential wires. This process achieves zero-delay and distortion-free image transmission, providing raw data for subsequent algorithm analysis.

[0013] The image acquisition resolution is 1920×1080, and the single-frame data transmission latency is ≤20ms, which meets the requirements of high-speed real-time detection.

[0014] The intelligent defect recognition and analysis module incorporates a lightweight defect detection algorithm and a standardized component image database. The database pre-stores standard images of defect-free automotive frame components of various specifications, as well as grayscale feature thresholds and size thresholds for four types of defects: rust, paint peeling, cracks, and missing parts. Accurate defect identification, location, and quantification are achieved through pixel-level difference comparison. After receiving the raw image data, the intelligent defect recognition and analysis module sequentially performs four steps: image preprocessing, pixel difference calculation, defect threshold determination, and defect parameter quantification, accurately outputting the defect coordinates, area, depth, and type parameters. ① The image preprocessing noise reduction formula is used to eliminate image noise caused by industrial dust and light interference. A two-dimensional Gaussian kernel function is used to smooth the image. The formula is:

[0015] In the formula: x and y are pixel coordinate offsets; σ is the standard deviation of Gaussian filtering, which is set to 1.5 in this system to balance noise reduction effect and image detail preservation.

[0016] ② The pixel grayscale difference comparison formula calculates the pixel-by-pixel grayscale difference between the image to be detected and the standard defect-free image to extract the defect feature region. The formula is:

[0017] In the formula: coordinates The grayscale difference of the pixels at that location; The grayscale value of the pixel in the image to be detected; This represents the grayscale value of the corresponding pixel in the standard image.

[0018] ③ The defect threshold determination formula sets the critical threshold for defect identification. (0-255 grayscale range), when > When a pixel is identified as a defective pixel, the area where consecutive defective pixels cluster together is the effective defect area. The formula is:

[0019] ④ Defect area quantification formula: Calculate the total number of pixels in the effective defect area, and combine this with the physical calibration coefficient of the image pixels to convert it into the actual defect area. Formula:

[0020] In the formula: The actual area of ​​the defect (mm) 2 ); This represents the total number of valid defective pixels. The actual physical area corresponding to a single pixel is calibrated to 0.01mm in this device. 2 / pixel.

[0021] ⑤ The defect similarity matching classification formula uses normalized correlation coefficients to match various defect features, achieving automatic defect classification. The formula is:

[0022] In the formula: The feature similarity coefficient; These are the grayscale feature values ​​of various standard defects in the database; The defect type corresponding to the maximum value is the current defect type.

[0023] After the algorithm completes its calculations, the module automatically removes isolated noise pixels and outputs four core parameters: defect center coordinates (X,Y), defect area S, defect depth level, and defect type. The digital signal is then transmitted to the multi-dimensional positioning and control module to complete the data interaction.

[0024] As a further aspect of the present invention, the multi-dimensional positioning and control module is the core of precise equipment alignment. After receiving defect coordinate parameters, it synchronously controls the coordinated movement of the placement unit's rotation axis, the moving unit's lateral displacement axis, and the angle adjustment mechanism's pitch axis through a built-in three-axis linkage control algorithm, achieving millimeter-level precise alignment. The module has a built-in coordinate transformation algorithm that converts image pixel coordinates into equipment mechanical physical coordinates, generating three-axis linkage adjustment pulse signals.

[0025] Circumferential rotation control: Based on the lateral offset of the defect, calculate the rotation angle of the drive motor, output pulse signals to control the forward and reverse rotation of the motor, and precisely start and stop it, thereby driving the driven turntable to rotate to compensate for the workpiece angle deviation; Lateral displacement control: Based on the longitudinal offset of the defect, the displacement distance of the rectangular moving bar is calculated, and the speed and number of rotations of the drive motor are controlled by pulse equivalent conversion. The horizontal displacement is achieved through gear and rack transmission. Pitch angle control: Based on the defect depth parameters, calculate the extension stroke of the telescopic cylinder, control the precise extension and retraction of the cylinder, and fine-tune the pitch angle of the high-definition industrial camera and the repair spray gun to ensure that the spraying axis is perpendicular to the defect plane.

[0026] Control formula: Mechanical displacement pulse conversion formula In the formula This is the actual displacement. To control the number of pulses, Single-pulse displacement equivalent (for this equipment) =0.01mm / pulse), with full closed-loop feedback correction, positioning error ≤±0.05mm.

[0027] The adaptive spraying control module enables intelligent adaptive adjustment of spraying parameters, abandoning the traditional fixed parameter spraying mode. It dynamically matches the spraying flow rate, spraying pressure, and spraying time according to the defect area and depth parameters, achieving precise quantitative spraying and eliminating problems such as overspraying, missed spraying, and material waste.

[0028] The adaptive spraying control module incorporates an adaptive fitting algorithm for spraying parameters, establishing a mathematical model corresponding to defect parameters and spraying parameters. It then uses an electronically controlled proportional valve to adjust the air pressure and powder output rate of the powder storage tank in real time, precisely controlling the spraying state of the repair spray gun. The algorithm formula is as follows: ① Adaptive formula for spraying flow rate:

[0029] In the formula: Real-time spraying flow rate (g / s); The baseline spraying flow rate; The defect area; Defect depth level; , To fit the correction coefficients, the equipment was calibrated and cured.

[0030] ② Adaptive formula for spraying time:

[0031] In the formula: For precise spraying time (s); The value for powder coating adhesion efficiency is 0.85 for this equipment.

[0032] The system outputs analog voltage signals to control the opening of the proportional valve based on the real-time calculated Q and T parameters, precisely adjusting the powder flow rate. At the same time, it controls the start and stop of the spray gun at regular intervals to ensure that the defective area is fully filled and the thickness is uniform, adapting to the repair needs of defects of different specifications.

[0033] As a further embodiment of the present invention, the precision servo drive module is the core of the equipment's power execution electronic control, and adopts a position-speed-current three-closed-loop servo control architecture, which is respectively connected to drive motor one, drive motor two, and telescopic cylinder.

[0034] After receiving the control command from the host computer, the module first performs position loop error correction, compares the commanded position with the real-time feedback position from the encoder, and calculates the position deviation; then it adjusts the motor speed through the speed loop to avoid start-stop shock. Finally, a current loop stabilizes the output torque, ensuring smooth power output. Feedback signals from the motor encoder and cylinder displacement sensor are collected in real time throughout the process, forming a closed-loop negative feedback control to correct mechanical operating errors in real time. Closed-loop control formula: PID dynamic adjustment formula:

[0035] In the formula: To control the output in real time; This represents the real-time position deviation. , , These are the proportional, integral, and derivative coefficients, which are optimized and fixed after equipment debugging to ensure the equipment's adjustment response speed and positioning accuracy.

[0036] The human-machine interface (HMI) control module is integrated into the industrial touchscreen control panel, serving as the system's HMI interface and enabling parameter configuration, mode switching, data visualization, and status monitoring. The electrical control principle is as follows: the control panel has a built-in configuration electrical control program that communicates in real-time with the PLC main control chip via an RS485 bus, supporting bidirectional data transmission. Users can manually input settings such as spray flow rate, stroke parameters, and defect thresholds via touchscreen, and these settings are synchronized to each functional module in real-time. Simultaneously, the system uploads operating parameters such as equipment speed, displacement stroke, defect identification data, repair progress, and fault codes to the touchscreen interface for visualized monitoring. The module supports automatic / manual dual-mode switching. In automatic mode, the system autonomously calculates and controls the entire process; in manual mode, it supports manual single-point control of each mechanism's actions, adapting to equipment debugging and special workpiece repair scenarios.

[0037] As a further aspect of the present invention, the fault self-detection and protection module 507 is the core of ensuring the safe operation of the equipment. It adopts real-time sampling and monitoring of electrical control logic, and collects the working current, voltage, displacement, and signal on / off status of each electrical component throughout the process, so as to realize fault prediction, real-time protection, and fault tracing.

[0038] The module incorporates a multi-channel AD sampling circuit, sampling the operating parameters of each actuator in real time at a frequency of 10ms / time and comparing them with the system's preset safety thresholds. When fault signals such as motor overload / overcurrent, cylinder jamming / abnormal displacement, camera signal interruption, spray gun clogging, or insufficient powder storage are detected, the hardware power-off protection circuit is immediately triggered, cutting off the equipment's power output, simultaneously latching the fault code, and displaying a 500 pop-up notification on the control screen, preventing mechanical damage and safety hazards caused by operating the equipment with defects. Simultaneously, the module has a fault data storage function, which can retain historical fault records, facilitating equipment maintenance and traceability, and significantly improving equipment operational stability and service life.

[0039] Compared with related technologies, the method and apparatus for repairing defects in the remanufacturing of automotive parts provided by the present invention have the following beneficial effects: This invention utilizes a high-definition industrial camera to acquire high-definition images of the entire workpiece. Combined with a pixel-level image comparison algorithm, it can accurately identify minute, hidden defects as small as 0.1mm, completely eliminating the drawbacks of traditional manual visual observation, such as large errors, missed detections, and false detections. Simultaneously, the system can automatically statistically analyze defect parameters and classify defect types, providing data support for precise repair. This significantly improves the accuracy of defect detection in automotive parts remanufacturing, effectively increases the yield rate of remanufactured parts, and ensures the performance and structural stability of remanufactured workpieces.

[0040] This invention employs a three-dimensional linkage adjustment structure involving workpiece rotation, lateral movement of the mechanism, and multi-angle micro-adjustment of the camera. Combined with an intelligent electronically controlled precision alignment system, it enables comprehensive adaptive adjustment of the workpiece's circumferential angle, the horizontal position of the repair mechanism, and the detection spraying angle. It perfectly adapts to the defect repair needs of automotive frame components with multi-curved surfaces, multiple edges and corners, and complex irregular structures. It can perform precise alignment repairs on automotive frame components of different specifications and sizes, overcoming the limitations of traditional equipment with fixed structures, single adjustments, and the ability to only adapt to simple planar repairs. The equipment's versatility and adaptability are significantly improved.

[0041] This invention achieves fully automated operation of the entire process—defect identification, coordinate analysis, precise alignment, adaptive spraying, re-inspection and error correction, and equipment reset—through the coordinated operation of seven major electronic control modules. It eliminates the need for manual positioning, adjustment, and spraying quantity control. Compared to traditional manual repair methods, it significantly reduces human intervention and labor intensity. Simultaneously, the closed-loop electronic control system can correct mechanical operating errors in real time, avoiding the tedious operation of repeated alignment adjustments. The efficient and continuous workflow improves batch repair efficiency and is suitable for the needs of industrialized mass remanufacturing production. Attached Figure Description

[0042] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0043] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a three-dimensional structural diagram of the angle adjustment mechanism in this invention; Figure 3 This is a frontal cross-sectional view of the angle adjustment mechanism in this invention; Figure 4 This is a three-dimensional structural diagram of the placement unit in this invention; Figure 5 This is a schematic diagram of the left cross-sectional structure of the mobile unit in this invention; Figure 6 This is a three-dimensional schematic diagram of the repair spray gun in this invention; Figure 7 The schematic diagram of the fully closed-loop intelligent electronic control defect repair system provided by the present invention.

[0044] In the diagram: 100, placement unit; 101, base; 102, placement plate; 103, driven turntable; 104, motor mounting slot; 105, drive motor one; 106, support block; 200. Mobile unit; 201. Rectangular bracket; 202. Rectangular mounting box; 203. Drive motor II; 204. Bevel gear I; 205. Bevel gear II; 206. Rotating shaft; 207. Gear; 208. Rectangular moving bar; 209. Driven rack; 2001. Rectangular mounting slot; 300. Angle adjustment mechanism; 301. Telescopic cylinder; 302. Limiting slider; 303. Hinge rod one; 304. Hinge block one; 305. High-definition industrial camera; 306. Hinge block two; 307. Hinge rod two; 308. Limiting connection port; 309. Wire; 400. Repair spraying unit; 401. Powder storage tank; 402. Spraying hose; 403. Repair spray gun; 500. Control Panel; 501. Image Acquisition and Transmission Module; 502. Intelligent Defect Recognition and Analysis Module; 503. Multi-Dimensional Positioning and Control Module; 504. Adaptive Spraying Control Module; 505. Precision Servo Drive Module; 506. Human-Machine Interaction Control Module; 507. Fault Self-Check and Protection Module. Detailed Implementation

[0045] Please refer to the following: Figure 1 and Figure 7 ,in, Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a three-dimensional structural diagram of the angle adjustment mechanism in this invention; Figure 3 This is a frontal cross-sectional view of the angle adjustment mechanism in this invention; Figure 4 This is a three-dimensional structural diagram of the placement unit in this invention; Figure 5 This is a schematic diagram of the left cross-sectional structure of the mobile unit in this invention; Figure 6 This is a three-dimensional schematic diagram of the repair spray gun in this invention; Figure 7 This is a schematic diagram of the principle of the fully closed-loop intelligent electronic control defect repair system provided by the present invention. The method and apparatus for repairing defects in the remanufacturing of automotive parts consists of five parts: a placement unit 100, a moving unit 200, an angle adjustment mechanism 300, a repair spraying unit 400, and a fully closed-loop intelligent electronic control defect repair system. It achieves automated scanning detection and precise spraying repair of defects in automotive frame parts. The specific implementation structure is as follows: The placement unit 100 serves as the equipment support base, including a base 101. A placement plate 102 is arranged parallel to the base 101. A driven turntable 103 is rotatably mounted at the center of the placement plate 102. The surface of the driven turntable 103 is used to support and place the automotive frame parts to be repaired. A motor mounting slot 104 is provided at the center of the top of the base 101. A drive motor 105 is fixedly installed on the inner wall of the bottom of the motor mounting slot 104. The vertical output shaft of the drive motor 105 passes through the placement plate 102 and is fixedly connected to the center of the bottom of the driven turntable 103, realizing the power rotation of the driven turntable 103.

[0046] Meanwhile, four support blocks 106 arranged in a rectangular array are fixedly installed on the top of the base 101. The tops of the four support blocks 106 are all fixedly welded to the bottom of the placement plate 102. The support blocks 106 provide stable support for the placement plate 102, ensuring its levelness and preventing wobbling or displacement during the placement and rotation of parts, thus ensuring the accuracy of subsequent repairs. The placement unit 100 is used to support the parts to be repaired and can rotate the parts and switch the spraying repair position according to the repair needs.

[0047] The mobile unit 200 is fixedly mounted on the top of the placement plate 102 of the placement unit 100, providing lateral movement power for the angle adjustment mechanism 300 and the repair spraying unit 400. It includes two symmetrically arranged rectangular supports 201, the bottoms of which are fixedly mounted on the top of the placement plate 102, arranged parallel and symmetrically to each other. A rectangular mounting box 202 is fixedly clamped between the opposing inner sidewalls of the two rectangular supports 201, achieving fixed positioning of the rectangular mounting box 202.

[0048] A second drive motor 203 is fixedly mounted on the top of a rectangular mounting box 202. The output shaft of the second drive motor 203 extends vertically into the internal cavity of the rectangular mounting box 202, and a first bevel gear 204 is fixedly mounted at the bottom end of the output shaft. A rotating shaft 206 is horizontally rotatable inside the rectangular mounting box 202. A second bevel gear 205 is fixedly mounted at one end of the rotating shaft 206, and the second bevel gear 205 meshes perpendicularly with the first bevel gear 204 for transmission. A toothed gear 207 is fixedly sleeved on the shaft 206, and the toothed gear 207 rotates synchronously with the rotating shaft 206.

[0049] A rectangular sliding bar 208 is horizontally inserted inside the rectangular mounting box 202. The two ends of the rectangular sliding bar 208 pass through the left and right side walls of the rectangular mounting box 202, allowing it to slide horizontally. A rectangular mounting groove 2001 is formed on the bottom inner wall of the rectangular sliding bar 208. A driven rack 209 is fixedly installed on the top inner wall of the rectangular mounting groove 2001. The driven rack 209 meshes with a toothed gear 207. Through the gear and rack transmission structure, the rotational power of the drive motor 203 is converted into the horizontal linear displacement of the rectangular sliding bar 208, realizing the lateral position adjustment of subsequent mechanisms.

[0050] An angle adjustment mechanism 300 is movably mounted on the top of the rectangular moving bar 208 of the mobile unit 200 for adaptive angle adjustment of the defect scanning equipment. It includes a telescopic cylinder 301, the bottom of which is fixedly mounted on the top end face of the rectangular moving bar 208. A limit connection port 308 is provided at the top of the rectangular moving bar 208, and a limit slider 302 is slidably mounted inside the limit connection port 308. The top of the limit slider 302 is fixedly connected to the end of the telescopic output shaft of the telescopic cylinder 301. The telescopic cylinder 301 extends and retracts, causing the limit slider 302 to slide horizontally along the limit connection port 308.

[0051] The bottom of the limiting slider 302 is hinged to a hinge rod 303, and the bottom end of the hinge rod 303 is hinged to a hinge block 304. The bottom of the rectangular moving bar 208 is fixedly hinged to a hinge rod 307, and the bottom end of the hinge rod 307 is fixedly connected to a hinge block 306. Both hinge blocks 304 and 306 are fixedly mounted on the housing of the high-definition industrial camera 305. Through the bidirectional hinged limiting of the two hinge rods, a four-bar fine-tuning structure for camera angle adjustment is formed. The high-definition industrial camera 305 is electrically connected to a wire 309 on its side, enabling real-time transmission of camera image data and providing image support for defect identification.

[0052] The repair spraying unit 400 is fixedly mounted on the top of the rectangular mounting box 202 of the mobile unit 200. It is used for powder spraying repair of defective parts. It includes a powder storage tank 401, the bottom of which is fixedly mounted on the top end face of the rectangular mounting box 202. The bottom left side of the powder storage tank 401 is fixedly connected to a spraying hose 402. The end of the spraying hose 402 away from the powder storage tank 401 is detachably connected to a repair spray gun 403. The detachable connection structure facilitates the replacement, inspection, and cleaning of the repair spray gun 403. The powder storage tank 401 stores repair powder, which is delivered to the repair spray gun 403 through the spraying hose 402 to complete the spraying repair operation.

[0053] The image acquisition and transmission module 501 relies on the high-definition industrial camera 305 to complete the real-time acquisition of full-area optical images of the surface of automotive frame parts. Through photoelectric conversion, the optical image signal is converted into a digital image electrical signal. With the help of differential anti-interference transmission logic, electromagnetic, light and dust interference in the industrial field are avoided, ensuring that the image signal is transmitted without distortion and with low latency. This provides complete, clear and reliable raw image data support for the back-end defect identification algorithm, realizing full-coverage visualization acquisition of the surface condition of the parts.

[0054] The intelligent defect recognition and analysis module 502 receives digital image data output by the image acquisition and transmission module 501. Through AI algorithms such as Gaussian noise reduction, pixel-level grayscale comparison, threshold determination, and feature matching, it automatically completes the identification, location, classification, and quantitative calculation of surface defects of parts. It accurately outputs the defect center coordinates, defect area, defect depth level, and defect type parameters, eliminates image noise interference, and avoids the problems of missed detection, false detection, and large errors in manual inspection. It provides accurate data basis for subsequent equipment alignment and adaptive spraying parameter adjustment.

[0055] The multi-dimensional positioning and control module 503 receives the defect quantification parameters and coordinate data output by the intelligent defect identification and analysis module 502. Through the pixel coordinate and mechanical physical coordinate conversion algorithm, it generates three-axis linkage precision adjustment commands to control the workpiece rotation angle of the placement unit 100, the lateral displacement distance of the moving unit 200, and the pitch fine adjustment angle of the angle adjustment mechanism 300, respectively. This enables the detection mechanism and the repair spray gun to be precisely aligned with the defect area at the millimeter level, adapting to the multi-angle precision positioning requirements of complex defects in irregularly shaped and multi-curved parts.

[0056] The adaptive spraying control module 504 is used to dynamically match the optimal spraying flow rate, spraying pressure and spraying time parameters based on the defect area and depth level parameters output by the defect identification and analysis module through the built-in adaptive fitting algorithm. It outputs electrical control signals to regulate the powder output rate of the powder storage tank and the working status of the repair spray gun. It can achieve precise spraying of different specifications of defects in terms of quantity, speed and time, avoiding problems such as overspray accumulation, missed spraying gaps and material waste, ensuring uniform thickness of defect repair and full filling, and realizing standardized adaptive repair operation.

[0057] The precision servo drive module 505 serves as the core of the closed-loop control for the power execution of the entire equipment. It receives action commands from various control modules and adopts a three-closed-loop PID control logic of position-speed-current to precisely drive drive motor 105, drive motor 203, and telescopic cylinder 301 to perform corresponding actions. It collects feedback signals from encoders and displacement sensors in real time and dynamically corrects operating deviations, eliminating mechanical start-stop shocks, displacement lag, and positioning offset problems, and ensuring the operating accuracy, stability, and response speed of each mechanical mechanism.

[0058] The human-machine interaction control module 506 is used to establish a two-way interaction channel between the equipment and the human. It is carried on the control screen 500 to realize functions such as manual configuration of equipment parameters, switching between automatic and manual operation modes, real-time visualization of equipment operation status, defect data statistics, and repair progress monitoring. It also supports fault data viewing, parameter storage and equipment debugging operations, taking into account the needs of automated unmanned operation and manual intervention debugging, and improving the convenience and adaptability of equipment operation.

[0059] The fault self-diagnosis and protection module 507 is used to sample and monitor the operating parameters of various electrical components and actuators of the equipment in real time, such as current, voltage, displacement, and signal continuity. It compares these parameters with the system's preset safety thresholds in real time, intelligently identifies fault states such as motor overload, cylinder jamming, camera signal interruption, spray gun blockage, and powder shortage, triggers hardware power-off protection and emergency stop mechanisms, simultaneously latches fault codes and pops up alarms, and retains fault tracing data. This prevents equipment from operating with faults, ensures safe and stable equipment operation, and extends the service life of the equipment. The present invention fixes and mounts a control screen 500 on a corresponding rectangular bracket 201. The control screen 500 has a built-in fully closed-loop intelligent electrical control defect repair system. The system adopts a four-layer core hardware architecture of "PLC main control + high-speed ARM computing chip + servo closed-loop drive + AI vision algorithm", abandoning the traditional single switch control mode and realizing deep coupling and linkage between the mechanical structure of the equipment and the electrical control algorithm.

[0060] The system follows a closed-loop control logic of "image acquisition → algorithm analysis → coordinate calculation → servo control → adaptive spraying → self-checking and error correction," precisely linking the placement unit 100, the moving unit 200, the angle adjustment mechanism 300, and the repair spraying unit 400 to achieve unmanned, high-precision, and standardized operation of the entire process of defect detection, positioning, repair, and re-inspection of automotive parts. The system comprises seven core functional modules, each with independent electronic control logic, proprietary algorithms, and linkage mechanisms. The complete technical principles, algorithm formulas, and electronic control processes are as follows: The image acquisition and transmission module 501 serves as the system's data input port, connecting to the high-definition industrial camera 305 and the wire 309. Utilizing the photoelectric conversion principle, it achieves precise conversion of optical images into digital electrical signals. Equipped with differential transmission anti-interference electrical control logic, it eliminates image distortion caused by electromagnetic interference in the industrial environment. Electrical control working principle: After the equipment is powered on, the PLC main control chip outputs a constant 5V low-voltage regulated power supply signal, which continuously powers the high-definition industrial camera 305 via wire 309. Simultaneously, it outputs a 30Hz synchronous trigger pulse to control the camera to acquire full-area images of the component surface frame by frame at a fixed frame rate. The camera's internal CMOS photosensitive element captures the optical image, converting the light signal into an analog electrical signal. This signal is then quantized into a 0-255 grayscale digital image signal by the internal AD conversion module and transmitted in real-time to the system's high-speed computing chip via the differential wire. This achieves delay-free and distortion-free image transmission throughout the process, providing raw data for subsequent algorithm analysis. Core technical parameters: Image acquisition resolution 1920×1080, single-frame data transmission delay ≤20ms, meeting the requirements of high-speed real-time detection.

[0061] The intelligent defect recognition and analysis module 502 is the core innovation of the system. It incorporates a lightweight defect detection algorithm and a standardized component image database. The database pre-stores standard images of defect-free automotive frame components of various specifications, as well as grayscale feature thresholds and size thresholds for four types of defects: rust, paint peeling, cracks, and missing parts. Through pixel-level difference comparison, it achieves accurate defect identification, location, and quantification, completely solving the problems of large errors and missed detection of minute defects in traditional manual inspection. Complete electronic control and algorithm principle: After receiving the raw image data, the module sequentially completes four steps: image preprocessing, pixel difference calculation, defect threshold determination, and defect parameter quantification. It accurately outputs the defect coordinates, area, depth, and type parameters. The calculation formula is as follows: ① Image preprocessing noise reduction formula: To eliminate image noise caused by industrial dust and light interference, a two-dimensional Gaussian kernel function is used to smooth the image. The formula is:

[0062] In the formula: x and y are pixel coordinate offsets; σ is the standard deviation of Gaussian filtering, which is set to 1.5 in this system to balance noise reduction effect and image detail preservation.

[0063] ② Pixel grayscale difference comparison formula: The defect feature region is extracted by performing pixel-by-pixel grayscale difference calculation between the image to be inspected and a standard defect-free image. The formula is:

[0064] In the formula: coordinates The grayscale difference of the pixels at that location; The grayscale value of the pixel in the image to be detected; This represents the grayscale value of the corresponding pixel in the standard image.

[0065] ③ Defect threshold determination formula Set a critical threshold for defect identification (0-255 grayscale range), when > When a pixel is identified as a defective pixel, the area where consecutive defective pixels cluster together is the effective defect area. The formula is:

[0066] ④ Defect area quantification formula The total number of pixels in the effective defect area is counted, and combined with the physical calibration coefficient of the image pixels, the actual defect area is calculated using the following formula:

[0067] In the formula: The actual area of ​​the defect (mm) 2 ); This represents the total number of valid defective pixels. The actual physical area corresponding to a single pixel is calibrated to 0.01mm in this device. 2 / pixel.

[0068] ⑤ Defect similarity matching classification formula Normalized correlation coefficients are used to match various defect features to achieve automatic defect classification. The formula is:

[0069] In the formula: The feature similarity coefficient; These are the grayscale feature values ​​of various standard defects in the database; The defect type corresponding to the maximum value is the current defect type.

[0070] After the algorithm completes its calculations, the module automatically removes isolated noise pixels and outputs four core parameters: defect center coordinates (X,Y), defect area S, defect depth level, and defect type. The digital signal is then transmitted to the multi-dimensional positioning and control module 503 to complete the data interaction.

[0071] The multi-dimensional positioning and control module 503 is the core of the equipment's precise alignment. After receiving the defect coordinate parameters, it uses a built-in three-axis linkage control algorithm to synchronously control the rotation axis of the placement unit, the lateral displacement axis of the moving unit, and the pitch axis of the angle adjustment mechanism to achieve millimeter-level precise alignment, solving the problems of large alignment deviations and lag in adjustment in traditional equipment. Electrical control working principle: The module has a built-in coordinate transformation algorithm that converts image pixel coordinates into the mechanical physical coordinates of the equipment, generating three-axis linkage adjustment pulse signals.

[0072] Circumferential rotation control: Based on the lateral offset of the defect, calculate the rotation angle of the drive motor 105, output pulse signals to control the forward and reverse rotation of the motor, and precisely start and stop it, thereby driving the driven turntable 103 to rotate to compensate for the workpiece angle deviation. Lateral displacement control: Based on the longitudinal offset of the defect, the displacement distance of the rectangular moving bar 208 is calculated. The speed and number of rotations of the drive motor 203 are controlled by pulse equivalent conversion. The horizontal displacement is achieved through gear and rack transmission. Pitch angle control: Based on the defect depth parameters, calculate the extension stroke of the telescopic cylinder 301, control the cylinder's precise extension and retraction, and fine-tune the pitch angle of the high-definition industrial camera 305 and the repair spray gun 403 to ensure the spraying axis is perpendicular to the defect plane. Core control formula: Mechanical displacement pulse conversion formula. In the formula This is the actual displacement. To control the number of pulses, Single-pulse displacement equivalent (for this equipment) =0.01mm / pulse), with full closed-loop feedback correction, positioning error ≤±0.05mm.

[0073] The adaptive spraying control module 504 achieves intelligent adaptive adjustment of spraying parameters, abandoning the traditional fixed-parameter spraying mode. It dynamically matches spraying flow rate, spraying pressure, and spraying time based on defect area and depth parameters, achieving precise quantitative spraying and eliminating overspray, underspray, and material waste. Electrical control working principle: The module has a built-in adaptive fitting algorithm for spraying parameters, establishing a mathematical model corresponding to defect parameters and spraying parameters. Through an electrically controlled proportional valve, it adjusts the air pressure and powder output rate of the powder storage tank 401 in real time, precisely controlling the spraying state of the repair spray gun 403. Core algorithm formula. ① Adaptive formula for spraying flow rate

[0074] In the formula: Real-time spraying flow rate (g / s); The baseline spraying flow rate; The defect area; Defect depth level; , To fit the correction coefficients, the equipment was calibrated and cured.

[0075] ② Adaptive formula for spraying time

[0076] In the formula: For precise spraying time (s); The value for powder coating adhesion efficiency is 0.85 for this equipment.

[0077] Electrical control execution logic: The system outputs analog voltage signals to control the opening of the proportional valve based on the real-time calculated Q and T parameters, accurately adjusts the powder flow rate, and controls the start and stop of the spray gun at regular intervals to ensure that the defect area is fully filled and the thickness is uniform, adapting to the repair needs of defects of different specifications.

[0078] The precision servo drive module 505 is the core of the equipment's power execution electronic control. It adopts a position-speed-current three-closed-loop servo control architecture, respectively connecting to drive motor 105, drive motor 203, and telescopic cylinder 301, solving the defects of traditional open-loop control such as low accuracy, easy deviation, and lag. The electronic control working principle is as follows: After receiving the control command from the host computer, the module first performs position loop error correction, comparing the commanded position with the real-time feedback position from the encoder to calculate the position deviation; then, it adjusts the motor's operating speed through the speed loop to avoid start-stop shock; finally, it stabilizes the output torque through the current loop to ensure smooth power output. Throughout the process, it collects feedback signals from the motor encoder and cylinder displacement sensor in real time, forming a closed-loop negative feedback control to correct mechanical operating errors in real time. The core closed-loop control formula is: PID dynamic adjustment formula.

[0079] In the formula: To control the output in real time; This represents the real-time position deviation. , , These are the proportional, integral, and derivative coefficients, which are optimized and fixed after equipment debugging to ensure the equipment's adjustment response speed and positioning accuracy.

[0080] The human-machine interface control module 506 is integrated into the industrial touch screen control panel 500, serving as the system's human-machine interface port. It enables parameter configuration, mode switching, data visualization, and status monitoring. The electrical control principle is as follows: the control panel has a built-in configuration electrical control program that communicates in real-time with the PLC main control chip via an RS485 bus, supporting bidirectional data transmission. Users can manually input settings such as spray flow rate, stroke parameters, and defect thresholds via touchscreen, and these settings are synchronized to each functional module in real-time. Simultaneously, the system uploads operating parameters such as equipment speed, displacement stroke, defect identification data, repair progress, and fault codes to the touchscreen interface for visualized monitoring. The module supports automatic / manual dual-mode switching. In automatic mode, the system autonomously calculates and controls the entire process; in manual mode, it supports manual single-point control of each mechanism, adapting to equipment debugging and special workpiece repair scenarios.

[0081] The fault self-diagnosis and protection module 507 is the core of ensuring safe operation of the equipment. It employs real-time sampling and monitoring of the electrical control logic, collecting data on the operating current, voltage, displacement, and signal continuity of each electrical component throughout the entire process, enabling fault prediction, real-time protection, and fault tracing. The electrical control working principle is as follows: The module has a built-in multi-channel AD sampling circuit that samples the operating parameters of each actuator in real time at a frequency of 10ms / time, comparing them with the system's preset safety thresholds. When fault signals such as motor overload / overcurrent, cylinder jamming / abnormal displacement, camera signal interruption, spray gun blockage, or insufficient powder are detected, the hardware power-off protection circuit is immediately triggered, cutting off the equipment's power output, simultaneously latching the fault code, and displaying a pop-up notification on the control screen 500, preventing mechanical damage and safety hazards caused by operating the equipment with faults. Simultaneously, the module has a fault data storage function, which can retain historical fault records, facilitating equipment maintenance and tracing, and significantly improving the equipment's operational stability and service life.

[0082] Repair spray gun: Model AZ3, adopts high-pressure atomization spray structure, is compatible with powder repair paint, supports adjustable spray nozzle diameter, and is suitable for precise spraying of minor defects in automotive frame parts.

[0083] Drive Motor 1 and Drive Motor 2: Both adopt servo speed-regulating motors with a rated operating voltage of 220V, a rated speed of 1500r / min, a positioning accuracy of ±0.1°, and support stepless speed regulation in both forward and reverse directions to meet precise positioning and adjustment requirements.

[0084] Telescopic cylinder: It adopts a precision micro servo cylinder with an effective telescopic stroke of 0-150mm and a telescopic accuracy of ±0.05mm. It can realize micro-stroke fine adjustment to meet the needs of precise multi-angle adjustment of the camera.

[0085] High-definition industrial camera: It adopts a high-definition pixel industrial imaging camera with 20 million pixels and an imaging frame rate of 30 frames / s. It supports high-definition shooting in low light and can accurately identify minute defects as small as 0.1mm.

[0086] Control panel: Adopts industrial touch screen display, supports touch operation, real-time data display, parameter storage and fault alarm, and the working temperature is adapted to industrial working environment of -10℃~60℃; The working principle of the method and apparatus for repairing defects in remanufacturing automotive parts provided by this invention is as follows: After the equipment is powered on, the electrical control defect repair system initializes and performs a self-test. The fault self-test and protection module 507 completes the testing of each electrical and mechanical mechanism. After confirming that there are no faults, it enters the standby state. The operator places the automotive frame parts to be remanufactured and repaired stably at the center of the driven turntable 103 of the placement unit 100. The placement plate 102 and the support block 106 form a stable load-bearing structure, ensuring that the workpiece is placed horizontally and without shaking, thus completing the preliminary preparation for the operation.

[0087] The operator initiates the fully automatic repair program via the control panel 500. The human-machine interface module 506 issues work instructions, and the image acquisition and transmission module 501 activates the high-definition industrial camera 305. Simultaneously, the system controls the telescopic cylinder 301 of the angle adjustment mechanism 300 through the precision servo drive module 505. The output shaft of the telescopic cylinder 301 extends and retracts, causing the limit slider 302 to slide horizontally along the limit connection port 308. The limit slider 302 pulls the first hinge rod 303 to move, cooperating with the fixed hinge limit of the second hinge rod 307, thereby driving the high-definition industrial camera 305 to complete multi-angle fine-tuning, achieving full-area image acquisition of the component surface without blind spots. The acquired image data is transmitted in real time to the intelligent defect recognition and analysis module 502 via the wire 309. After comparison and analysis by AI algorithms, the coordinates, area, depth, and type of defects on the workpiece surface are accurately located, and defect repair parameter instructions are generated.

[0088] Based on the defect coordinate parameters, the system issues multiple adjustment commands through the multi-dimensional positioning and control module 503: First, it controls the drive motor 105 of the placement unit 100 to work, and the output shaft of the drive motor 105 drives the driven turntable 103 to rotate precisely, adjusting the circumferential angle of the workpiece so that the defect area is in the optimal repair position; Second, it controls the drive motor 203 of the moving unit 200 to work, and the drive motor 203 drives the bevel gear 204 to rotate, which drives the bevel gear 205 and the rotating shaft 206 to rotate synchronously through meshing transmission. The rotating shaft 206 drives the toothed gear 207 to rotate, and the toothed gear 207 meshes to drive the driven rack 209 to move, thereby driving the rectangular moving bar 208 to move horizontally, completing the precise horizontal alignment of the camera and the repair spray gun 403; Third, it finely adjusts the stroke of the telescopic cylinder 301 again to calibrate the tilt angle of the high-definition industrial camera 305 and the repair spray gun 403 to ensure that the spray gun nozzle is vertically aligned with the center area of ​​the defect, completing the precise alignment.

[0089] After alignment, the adaptive spraying control module 504 starts the repair spraying unit 400, automatically matching the spraying flow rate, pressure, and duration according to the defect parameters. Repair powder inside the powder storage tank 401, under electronically controlled pressure regulation, is delivered to the repair spray gun 403 via the spraying hose 402. The repair spray gun 403 then activates high-pressure atomization spraying, precisely targeting the defective area of ​​the workpiece to complete repair operations such as rust filling, paint peeling repair, and crack sealing. For large-area defects, the spraying volume is automatically increased and the spraying time extended; for small defects, precise micro-spraying is applied, avoiding material waste and repair buildup.

[0090] After a single spraying operation is completed, the equipment restarts the high-definition industrial camera 305 for scanning and inspection. The intelligent defect recognition and analysis module 502 compares the repaired workpiece image with the image to determine whether the defect has been completely repaired. If there are unrepaired areas, the system automatically repeats the alignment and spraying process until the defect is completely eliminated. If the repair is satisfactory, the equipment resets to its original position, completing the remanufacturing defect repair operation for a single workpiece, and awaits the next operation instruction.

[0091] Throughout the entire operation, the fault self-check and protection module 507 monitors the equipment's operating status in real time. If any abnormality occurs, it will immediately stop the machine for protection and issue an alarm. The servo drive module provides closed-loop control throughout the process, correcting mechanical operating errors and ensuring operational accuracy and stability.

[0092] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments, or they can be used directly or indirectly, without departing from the principles and spirit of the invention. In other related technical fields, the scope of the invention is defined by the appended claims and their equivalents, and they are similarly included within the scope of patent protection of the invention.

Claims

1. A device for repairing defects in the remanufacturing of automotive parts, characterized in that, include: It consists of several parts: placement unit, mobile unit, angle adjustment mechanism, and repair spraying unit; The placement unit includes a base, a placement plate on top of the base, a driven turntable rotatably mounted on the placement plate, automotive frame parts placed on the driven turntable, and a drive motor mounted on the top of the base. The output shaft of the drive motor is fixedly connected to the bottom of the driven turntable. The placement unit is used to place automotive frame parts on a driven turntable and rotate the spraying and repair direction as needed.

2. The automotive parts remanufacturing defect repair device according to claim 1, characterized in that: The base has a motor mounting slot at the top, and the drive motor is fixedly mounted on the bottom inner wall of the motor mounting slot. Four support blocks arranged in a rectangular array are fixedly mounted on the top of the base, and the top of the support blocks is fixedly connected to the bottom of the placement plate.

3. The automotive parts remanufacturing defect repair device according to claim 1, characterized in that: The mobile unit is mounted on the placement unit, and the mobile unit includes two rectangular supports, both of which are fixedly installed on the top of the placement plate. The mobile unit also includes a rectangular mounting box, a second drive motor, a first bevel gear, a second bevel gear, a rotating shaft, a toothed gear, a rectangular moving bar, a driven rack, and a rectangular mounting slot. The rectangular mounting box is positioned between two rectangular supports, and the two rectangular supports are fixedly connected to the rectangular mounting box on the side closest to each other. The second drive motor is fixedly mounted on the top of the rectangular mounting box, and the output shaft of the second drive motor extends into the rectangular mounting box; The first bevel gear is fixedly mounted on the output shaft of the second drive motor, and the first bevel gear is located inside the rectangular mounting box; The second bevel gear is disposed inside a rectangular mounting box, and the second bevel gear meshes with the first bevel gear; The rotating shaft is rotatably installed in a rectangular mounting box, and one end of the rotating shaft is fixedly connected to a bevel gear. The toothed gear is fixedly sleeved on the rotating shaft; The rectangular moving strip is set inside the rectangular mounting box, and both ends of the rectangular moving strip pass through the rectangular mounting box. The rectangular mounting groove is formed on the bottom inner wall of the rectangular moving strip; The driven rack is fixedly installed on the top inner wall of the rectangular mounting slot, and the driven rack meshes with the toothed gear; The mobile unit is used for the subsequent left and right movement of the angle adjustment mechanism.

4. The automotive parts remanufacturing defect repair device according to claim 1, characterized in that: The angle adjustment mechanism is movably mounted on the mobile unit, and the angle adjustment mechanism includes a telescopic cylinder, which is fixedly mounted on the top of the rectangular moving bar. The angle adjustment mechanism also includes a limiting slider, a hinge rod one, a hinge block one, a high-definition industrial camera, a hinge block two, a hinge rod two, the limiting connection port, and wires. The limiting slider is fixedly installed on the output shaft of the telescopic cylinder, and the limiting slider is slidably installed on the rectangular moving bar; The hinge rod is hinged to the bottom of the limiting slider; The hinge block one is hinged to the bottom end of the hinge rod one; The high-definition industrial camera is positioned below the rectangular moving bar, and the hinge block is fixedly mounted on the high-definition industrial camera. The second hinge block is fixedly installed on the high-definition industrial camera; The second hinge rod is hingedly mounted on the second hinge block, and the top end of the second hinge rod is fixedly connected to the bottom of the rectangular moving bar; The limiting connection port is located at the top of the rectangular moving bar, and the limiting slider is slidably connected to the limiting connection port. The wire is electrically connected to the high-definition industrial camera; The angle adjustment mechanism is used for scanning and inspection, scanning and observing the location of parts that need repair on automotive frame components, and can adjust the shooting angle of the high-definition industrial camera as needed.

5. The automotive parts remanufacturing defect repair device according to claim 1, characterized in that: The repair spraying unit includes a powder storage tank, which is fixedly installed on the top of a rectangular mounting box; The repair spraying unit also includes several parts such as a spraying hose and a repair spray gun; The spraying hose is fixedly connected to the left side of the powder storage tank; The repair spray gun is detachably connected to the end of the spray hose away from the powder storage tank. The repair spray gun is model AZ3; The repair spraying unit is mounted on a mobile unit and is used for powder spraying repair of defective parts.

6. A method for repairing defects in the remanufacturing of automotive parts, characterized in that: The automotive parts remanufacturing defect repair device as described in claims 1 to 5 includes a control screen and a fully closed-loop intelligent electronic control defect repair system installed inside the control screen, wherein the control screen is fixedly installed on the outside of a corresponding rectangular bracket. The fully closed-loop intelligent electronic control defect repair system mainly includes: The image acquisition and transmission module relies on a high-definition industrial camera to complete the real-time acquisition of full-area optical images of the surface of automotive frame components. An intelligent defect identification and analysis module is used to receive digital image data output by an image acquisition and transmission module. A multi-dimensional positioning and control module is used to receive defect quantification parameters and coordinate data output by the intelligent defect identification and analysis module; An adaptive spraying control module, wherein the adaptive spraying control module uses the defect area and depth level parameters output by the defect identification and analysis module; The precision servo drive module serves as the core of the closed-loop control for the power execution of the entire device, and receives action commands from various control modules. The human-machine interaction control module is used to establish a two-way interaction channel between the equipment and the human, and is carried on the control screen to realize functions such as manual configuration of equipment parameters, switching between automatic / manual operation modes, real-time visual display of equipment operating status, defect data statistics, and repair progress monitoring. The fault self-diagnosis and protection module can sample and monitor the operating parameters of various electrical components and actuators of the equipment in real time, such as current, voltage, displacement, and signal continuity.

7. The method for repairing defects in the remanufacturing of automotive parts according to claim 6, characterized in that: The image acquisition and transmission module is the system data input port, which is core-connected to a high-definition industrial camera and wires. It relies on the photoelectric conversion principle to achieve accurate conversion of optical images into digital electrical signals. It is equipped with differential transmission anti-interference electrical control logic to eliminate image distortion caused by electromagnetic interference in the industrial environment. After the equipment is powered on, the PLC main control chip outputs a constant 5V low-voltage regulated power supply signal, which continuously powers the high-definition industrial camera via wires. At the same time, it outputs a 30Hz synchronous trigger pulse to control the camera to acquire full-area images of the component surface frame by frame at a fixed frame rate. The camera's internal CMOS photosensitive element captures optical images, converts the light signals into analog electrical signals, and quantizes them into 0-255 grayscale digital image signals through the internal AD conversion module. These signals are then transmitted in real time to the system's high-speed computing chip via differential wires, achieving zero-delay and distortion-free image transmission throughout the process, providing raw data for subsequent algorithm analysis. The image acquisition resolution is 1920×1080, and the single-frame data transmission latency is ≤20ms, which meets the requirements of high-speed real-time detection. The intelligent defect recognition and analysis module 502 incorporates a lightweight defect detection algorithm and a standardized component image database. The database pre-stores standard images of defect-free automotive frame components of various specifications, as well as grayscale feature thresholds and size thresholds for four types of defects: rust, paint peeling, cracks, and missing parts. Through pixel-level difference comparison, it achieves accurate defect recognition, location, and quantification. After receiving the raw image data, the intelligent defect recognition and analysis module 502 sequentially completes four steps: image preprocessing, pixel difference calculation, defect threshold determination, and defect parameter quantification, accurately outputting defect coordinates, area, depth, and type parameters. ① The image preprocessing noise reduction formula is used to eliminate image noise caused by industrial dust and light interference. A two-dimensional Gaussian kernel function is used to smooth the image. The formula is: In the formula: x and y are pixel coordinate offsets; σ is the standard deviation of Gaussian filtering, which is set to 1.5 in this system to balance noise reduction effect with image detail preservation. ② The pixel grayscale difference comparison formula calculates the pixel-by-pixel grayscale difference between the image to be detected and the standard defect-free image to extract the defect feature region. The formula is: In the formula: coordinates The grayscale difference of the pixels at that location; The grayscale value of the pixel in the image to be detected; This refers to the grayscale value of the corresponding pixel in the standard image. ③ The defect threshold determination formula sets the critical threshold for defect identification. (0-255 grayscale range), when > When a pixel is identified as a defective pixel, the area where consecutive defective pixels cluster together is the effective defect area. The formula is: ④ The defect area quantification formula calculates the actual defect area by statistically counting the total number of pixels in the effective defect area and combining it with the physical calibration coefficient of the image pixels. The formula is: In the formula: The actual area of ​​the defect (mm) 2 ); This represents the total number of valid defective pixels. The actual physical area corresponding to a single pixel is calibrated to 0.01mm in this device. 2 / pixel; ⑤ The defect similarity matching classification formula uses normalized correlation coefficients to match various defect features, achieving automatic defect classification. The formula is: In the formula: The feature similarity coefficient; These are the grayscale feature values ​​of various standard defects in the database; The defect type corresponding to the maximum value is the current defect type; After the algorithm completes its calculations, the module automatically removes isolated noise pixels and outputs four core parameters: defect center coordinates (X,Y), defect area S, defect depth level, and defect type. The digital signal is then transmitted to the multi-dimensional positioning and control module to complete the data interaction.

8. The method for repairing defects in the remanufacturing of automotive parts according to claim 6, characterized in that: The multi-dimensional positioning and control module is the core of the equipment's precise alignment. After receiving the defect coordinate parameters, it uses a built-in three-axis linkage control algorithm to synchronously control the rotation axis of the placement unit, the lateral displacement axis of the moving unit, and the pitch axis of the angle adjustment mechanism to achieve millimeter-level precise alignment. The module has a built-in coordinate transformation algorithm that converts image pixel coordinates into equipment mechanical physical coordinates, generating a three-axis linkage adjustment pulse signal. Circumferential rotation control: Based on the lateral offset of the defect, calculate the rotation angle of the drive motor, output pulse signals to control the forward and reverse rotation of the motor, and precisely start and stop it, thereby driving the driven turntable to rotate to compensate for the workpiece angle deviation; Lateral displacement control: Based on the longitudinal offset of the defect, the displacement distance of the rectangular moving bar is calculated, and the speed and number of rotations of the drive motor are controlled by pulse equivalent conversion. The horizontal displacement is achieved through gear and rack transmission. Pitch angle control: Calculate the extension stroke of the telescopic cylinder based on the defect depth parameters, control the precise extension and retraction of the cylinder, and fine-tune the pitch angle of the high-definition industrial camera and the repair spray gun to ensure that the spraying axis is perpendicular to the defect plane. Control formula: Mechanical displacement pulse conversion formula In the formula This is the actual displacement. To control the number of pulses, Single-pulse displacement equivalent (for this equipment) =0.01mm / pulse), with full-process closed-loop feedback correction, positioning error ≤±0.05mm; The adaptive spraying control module realizes intelligent adaptive adjustment of spraying parameters, abandons the traditional fixed parameter spraying mode, and dynamically matches the spraying flow rate, spraying pressure and spraying time according to the defect area and depth parameters to achieve precise quantitative spraying and eliminate the problems of overspraying, missed spraying and material waste. The adaptive spraying control module incorporates an adaptive fitting algorithm for spraying parameters, establishing a mathematical model corresponding to defect parameters and spraying parameters. It then uses an electronically controlled proportional valve to adjust the air pressure and powder output rate of the powder storage tank in real time, precisely controlling the spraying state of the repair spray gun. The algorithm formula is as follows: ① Adaptive formula for spraying flow rate: In the formula: Real-time spraying flow rate (g / s); The baseline spraying flow rate; The defect area; Defect depth level; , To obtain the fitting correction coefficients, the equipment was calibrated and solidified. ② Adaptive formula for spraying time: In the formula: For precise spraying time (s); For the powder coating adhesion efficiency, this equipment uses a value of 0.85; The system outputs analog voltage signals to control the opening of the proportional valve based on the real-time calculated Q and T parameters, precisely adjusting the powder flow rate. At the same time, it controls the start and stop of the spray gun at regular intervals to ensure that the defective area is fully filled and the thickness is uniform, adapting to the repair needs of defects of different specifications.

9. The method for repairing defects in the remanufacturing of automotive parts according to claim 6, characterized in that: The precision servo drive module is the core of the equipment's power execution electronic control. It adopts a position-speed-current three-closed-loop servo control architecture and is respectively connected to drive motor one, drive motor two, and telescopic cylinder. After receiving the control command from the host computer, the module first performs position loop error correction, compares the commanded position with the real-time feedback position from the encoder, and calculates the position deviation; then it adjusts the motor speed through the speed loop to avoid start-stop shock. Finally, the output torque is stabilized through a current loop to ensure smooth power output; feedback signals from the motor encoder and cylinder displacement sensor are collected in real time throughout the process to form a closed-loop negative feedback control, which corrects mechanical operating errors in real time; closed-loop control formula: PID dynamic adjustment formula: In the formula: To control the output in real time; This represents the real-time position deviation. , , These are the proportional, integral, and derivative coefficients, which are optimized and fixed after equipment debugging to ensure the equipment's adjustment response speed and positioning accuracy. The human-machine interaction control module is mounted on an industrial touch control screen and serves as the system's human-machine interaction port, enabling parameter configuration, mode switching, data visualization, and status monitoring functions. The control panel has a built-in configuration electrical control program and communicates with the PLC main control chip in real time via RS485 bus, supporting bidirectional data transmission. Manual input of settings such as spray flow rate, stroke parameters, and defect thresholds is possible via touch screen, and these settings are synchronized to each functional module in real time. Simultaneously, the system uploads operating parameters such as equipment speed, displacement stroke, defect identification data, repair progress, and fault codes to the touch screen interface in real time, enabling visual monitoring. The module supports automatic / manual dual-mode switching. In automatic mode, the system autonomously calculates and controls the entire process, while in manual mode, manual single-point control of each mechanism is supported, adapting to equipment debugging and special workpiece repair scenarios.

10. The method for repairing defects in the remanufacturing of automotive parts according to claim 6, characterized in that: The fault self-diagnosis and protection module is the core of ensuring the safe operation of the equipment. It adopts real-time sampling and monitoring of electrical control logic, and collects the working current, voltage, displacement and signal on / off status of each electrical component throughout the process to realize fault prediction, real-time protection and fault tracing. The module has a built-in multi-channel AD sampling circuit that samples the operating parameters of each actuator in real time at a frequency of 10ms / time and compares them with the system's preset safety threshold. When fault signals such as motor overload and overcurrent, cylinder jamming and abnormal displacement, camera signal interruption, spray gun blockage, and powder shortage are detected, the hardware power-off protection circuit is immediately triggered to cut off the equipment's power output, simultaneously latch the fault code and display a pop-up message on the control screen, preventing mechanical damage and safety hazards caused by operating the equipment with faults. At the same time, the module has a fault data storage function, which can retain historical fault records, facilitate equipment maintenance and traceability, and greatly improve the equipment's operational stability and service life.

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