A metal mesh surface deformation real-time monitoring system

Abstract

The utility model belongs to metal screen surface production technical field, specifically disclose a kind of metal screen surface deformation real-time monitoring system, including sensor module, speed control module, central control module, power module and display module;Sensor module's signal output end is connected with the signal input end of central control module;Speed control module and central control module between signal two-way intercommunication;The signal output of central control module to display module;Power module is electrically connected with sensor module, central control module and display module respectively;Sensor module includes at least one photoelectric sensor, and photoelectric sensor is arranged below the metal screen surface at the junction of electrostatic spraying and high-temperature curing two processes;Speed control module includes the frequency converter of the motor of control metal screen surface movement.The utility model can monitor screen surface deformation in real time, timely adjust speed to reduce screen surface deformation and alarm warning.The utility model is suitable for deformation monitoring when metal screen surface production.

Description

Technical Field

[0001] This utility model belongs to the field of metal mesh production technology and relates to a real-time monitoring system for metal mesh deformation. Background Technology

[0002] Electrostatic spraying technology for metal mesh, as a core process in modern surface treatment, has been widely applied in automobile manufacturing, home appliance production, architectural decoration, and electronics. This technology uses an electrostatic field to uniformly adsorb coating particles onto the surface of a metal substrate, achieving a coating utilization rate of over 80% and effectively reducing environmental pollution. Especially for complex-shaped metal mesh structures, electrostatic spraying can achieve efficient coating coverage and improved adhesion. However, deformation issues during the subsequent high-temperature curing process have become a key bottleneck restricting the stability of the process. During high-temperature curing, the metal mesh surface is prone to plastic deformation due to the combined effects of thermal and structural stress. Specifically, thermal expansion and contraction cause changes in the mesh's dimensions, and increased creep in localized high-temperature areas, leading to deformation phenomena such as sagging and overall warping at the junction of the electrostatic spraying and high-temperature curing processes. In existing processes, this deformation causes contact friction between the mesh surface and the equipment structure (i.e., "mesh rubbing"), resulting in coating scratches, uneven thickness, and other defects, severely impacting product yield. Industry data shows that this problem is particularly prominent in the spraying production of thin-walled metal products such as aluminum and stainless steel mesh. Current solutions mostly focus on surface protection or parameter adjustment, but cannot fundamentally solve the structural problems caused by high-temperature deformation. Attempts to mitigate sagging by adding support points or pre-deformation designs have the following limitations: 1) The contact points between the support structure and the mesh surface create a "shielding effect," leading to missing or excessively thin coatings in that area, interfering with coating uniformity; 2) The amount of pre-deformation is difficult to adapt to the thermal deformation characteristics of different mesh materials. These problems necessitate continuous manual monitoring of the metal mesh sagging during production and constant equipment adjustments, resulting in significant waste of manpower and resources. Therefore, a solution that can monitor mesh deformation in real time and issue timely alarms is urgently needed to replace inefficient manual monitoring and reduce losses. Summary of the Invention

[0003] The purpose of this invention is to provide a real-time monitoring system for metal mesh deformation, which can monitor mesh deformation in real time, adjust the speed in a timely manner to reduce mesh deformation, and issue an alarm, thereby reducing labor costs and improving production efficiency.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A real-time monitoring system for deformation of a metal mesh includes a sensor module, a speed control module, a central control module, a power supply module, and a display module. The signal output terminal of the sensor module is connected to the signal input terminal of the central control module; the speed control module and the central control module have bidirectional signal communication; the signal input terminal of the display module is connected to the signal output terminal of the central control module. The power supply module is electrically connected to the sensor module, the central control module, and the display module, respectively. The sensor module includes at least one photoelectric sensor, which is located below the metal mesh at the junction of the electrostatic spraying and high-temperature curing processes. The speed control module includes a frequency converter for a motor that controls the movement of the metal mesh surface.

[0005] As a limitation, it also includes an audible and visual alarm module, the signal input terminal of which is connected to the signal output terminal of the central control module; The power supply module is electrically connected to the audible and visual alarm module.

[0006] As a further limitation, when the photoelectric sensor is blocked by the metal mesh, the sensor module outputs a blocking signal to the central control module. The central control module receives and responds to the obstruction signal, generates a deceleration signal and transmits it to the speed control module, and generates an alarm signal and transmits it to the audible and visual alarm module. The speed control module receives and responds to the deceleration signal, reducing the moving speed of the metal mesh surface; The audible and visual alarm module receives and responds to alarm signals, emitting audible and visual alarms. The speed control module continuously generates current speed information and transmits it to the central control module. The central control module then transmits the obstruction signal and current speed information to the display module.

[0007] As a second limitation, the photoelectric sensor is a through-beam photoelectric sensor.

[0008] As a third limitation, the central control module is a control circuit based on STM32 series chips.

[0009] The technological advancements achieved by this invention compared to existing technologies, due to the adoption of the aforementioned technical solution, are as follows: This invention features a linkage response mechanism for signal obstruction from a photoelectric sensor. By monitoring the obstruction state caused by mesh deformation in real time, it automatically triggers speed reduction control and audible and visual alarms. This enables immediate intervention in deformations such as mesh sagging and warping during the high-temperature curing process, significantly improving process stability. The speed reduction response of the speed control module effectively mitigates the risk of friction between the mesh and the equipment, avoiding coating scratches and uneven thickness caused by "mesh rubbing." The audible and visual alarm module immediately alerts operators, reducing the need for manual inspections and lowering labor costs. Simultaneously, the central control module synchronizes the obstruction signal and current speed information to the display module, providing data support for process optimization. This linkage response mechanism, together with the previous sensor monitoring, power supply, and display module, forms a closed-loop control system, fundamentally solving the problem of decreased yield caused by high-temperature deformation. It is particularly suitable for the complex structure spraying production of thin-walled products such as aluminum and stainless steel mesh, greatly improving production efficiency and product consistency.

[0010] This invention belongs to the field of metal mesh production technology. It can monitor mesh deformation in real time, adjust the speed in time to reduce mesh deformation and provide alarm reminders, thereby freeing up labor costs and improving production efficiency. Attached Figure Description

[0011] The accompanying drawings are provided to further understand the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation thereof.

[0012] In the attached diagram: Figure 1 This is a structural block diagram of an embodiment of the present utility model. Detailed Implementation

[0013] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0014] Example like Figure 1 As shown, this embodiment is a real-time monitoring system for deformation of metal mesh, including a sensor module, a speed control module, a central control module, a power supply module, an audible and visual alarm module, and a display module.

[0015] The signal output terminal of the sensor module is connected to the signal input terminal of the central control module. The speed control module and the central control module communicate bidirectionally. The signal input terminal of the audible and visual alarm module is connected to the signal output terminal of the central control module. The signal input terminal of the display module is connected to the signal output terminal of the central control module.

[0016] The power supply module is electrically connected to the sensor module, central control module, audible and visual alarm module, and display module respectively, providing power.

[0017] The sensor module includes a photoelectric sensor, which is a through-beam photoelectric sensor, located below the metal mesh at the junction of the electrostatic spraying and high-temperature curing processes.

[0018] The speed control module includes a frequency converter for the motor that controls the movement of the metal mesh surface.

[0019] The central control module is a control circuit based on STM32 series chips.

[0020] In this embodiment, the photoelectric sensor is placed below the metal mesh. When the metal mesh deforms and blocks the photoelectric sensor, there will be no mesh rubbing. At this time, the sensor module outputs a blocking signal to the central control module.

[0021] The central control module receives and responds to the obstruction signal output by the sensor module, generating a deceleration signal which is transmitted to the speed control module, and an alarm signal which is transmitted to the audible and visual alarm module. The speed control module receives and responds to the deceleration signal, causing the motor driving the metal mesh to slow down under the control of the frequency converter, thereby reducing the movement speed of the metal mesh and minimizing deformation. The audible and visual alarm module receives and responds to the alarm signal, emitting an audible and visual alarm to alert personnel. If the alarm continues uninterrupted for an extended period, it indicates that controlling the movement speed of the metal mesh alone is insufficient to eliminate the risk of unauthorized access, and manual intervention is required.

[0022] In this embodiment, during operation, the speed control module continuously generates current speed information and transmits it to the central control module. The central control module then transmits the occlusion signal and current speed information to the display module, which displays the status of the photoelectric sensor and the current movement speed of the metal mesh surface.

[0023] In this embodiment, the number of photoelectric sensors is one, but it can be increased according to the actual situation, as long as it can ensure that the deformation of the metal mesh surface can be monitored in a timely manner.

[0024] In summary, this embodiment can monitor mesh deformation in real time, adjust the speed in a timely manner to reduce mesh deformation, and issue alarms, thereby reducing labor costs and improving production efficiency.

Claims

1. A metal mesh surface deformation real-time monitoring system, characterized in that, It includes a sensor module, a speed control module, a central control module, a power supply module, and a display module; The signal output terminal of the sensor module is connected to the signal input terminal of the central control module; the speed control module and the central control module have bidirectional signal communication; the signal input terminal of the display module is connected to the signal output terminal of the central control module. The power supply module is electrically connected to the sensor module, the central control module, and the display module, respectively. The sensor module includes at least one photoelectric sensor, which is located below the metal mesh at the junction of the electrostatic spraying and high-temperature curing processes. The speed control module includes a frequency converter for a motor that controls the movement of the metal mesh surface.

2. The real-time monitoring system for deformation of a metal mesh according to claim 1, characterized in that, It also includes an audible and visual alarm module, whose signal input terminal is connected to the signal output terminal of the central control module; The power supply module is electrically connected to the audible and visual alarm module.

3. The metal mesh deformation real-time monitoring system according to claim 2, characterized in that, When the photoelectric sensor is blocked by the metal mesh, the sensor module outputs a blocking signal to the central control module. The central control module receives and responds to the obstruction signal, generates a deceleration signal and transmits it to the speed control module, and generates an alarm signal and transmits it to the audible and visual alarm module. The speed control module receives and responds to the deceleration signal, reducing the moving speed of the metal mesh surface; The audible and visual alarm module receives and responds to alarm signals, emitting audible and visual alarms. The speed control module continuously generates current speed information and transmits it to the central control module. The central control module then transmits the obstruction signal and current speed information to the display module.

4. A real-time monitoring system for deformation of a metal mesh according to any one of claims 1 to 3, characterized in that, The photoelectric sensor is a through-beam photoelectric sensor.

5. The system according to any one of claims 1 to 3, wherein The central control module is a control circuit based on STM32 series chips.

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