Intelligent explosion spraying system and control method

Abstract

This invention discloses an intelligent explosive spraying system and control method. The system includes: an explosive spraying device for inputting fuel, oxidizer, and powder, and generating a high-temperature, high-pressure gas flow upon ignition to bombard the powder onto the surface of the workpiece to form a coating; a vector spray gun for adaptive extension and retraction adjustment based on the structural information of the workpiece; a data acquisition system for real-time acquisition of the spraying process of the explosive spraying device and the state of the workpiece; and a control system for receiving signals transmitted from the data acquisition system and controlling the explosive spraying device to dynamically adjust the spraying state and / or the vector spray gun to extend and retract. This invention adjusts the spraying process based on the explosive spraying device and the condition of the workpiece, monitoring and dynamically adjusting the spraying process in real time. This gives the explosive spraying system active control and self-adjustment functions, significantly improving the flexibility, practicality, spraying efficiency, and coating quality of the explosive spraying system.

Description

Technical Field

[0001] This invention relates to the field of explosive spraying technology, and more specifically to an intelligent explosive spraying system and control method. Background Technology

[0002] Thermal spraying is a technology that involves heating and melting coating materials and then spraying them at high speed onto the surface of a substrate to form a coating. This includes supersonic flame spraying, plasma spraying, and detonation spraying. Detonation spraying (D-Gun), invented in the 1950s, involves premixing fuel (usually acetylene) and an oxidizer (usually oxygen) and feeding them into a sealed cylindrical tube, closed at one end and open at the other. An igniter then ignites the mixture, creating a high-temperature, high-pressure gas flow that heats and accelerates the powder before it bombards the surface of the workpiece to form a coating. Due to its superior coating quality, it is widely used in aerospace, power, and energy fields.

[0003] While explosive spraying technology has advantages that other thermal spraying technologies cannot match, existing explosive spraying systems have low levels of intelligence, imperfect control methods, fixed spraying methods, and cannot adjust the spraying according to the condition of the workpiece to be sprayed. They also cannot monitor and dynamically adjust the spraying process in real time, resulting in poor spraying effect and coating quality being severely affected by the explosion and combustion.

[0004] In addition, existing explosive spraying systems also have drawbacks such as low efficiency, bulky size, and low flexibility. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the problems that existing explosive spraying systems cannot adjust the spraying according to the condition of the workpiece to be sprayed and cannot monitor and dynamically adjust the spraying process in real time, thereby providing an intelligent explosive spraying system and control method.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] An intelligent explosive spraying system, comprising:

[0008] An explosive spraying device is used to input fuel, oxidant, and powder, and generate a high-temperature and high-pressure gas flow when ignited, so that the powder bombards the surface of the workpiece to be sprayed to form a coating.

[0009] Also includes:

[0010] The vector spray gun is located at the powder outlet end of the explosive spraying device and adaptively extends and retracts according to the structural information of the workpiece to be sprayed.

[0011] The data acquisition system is used to collect data in real time on the spraying process of the explosive spraying device and the status of the workpiece to be sprayed.

[0012] The control system is used to receive signals transmitted by the acquisition system and control the explosive spraying device to dynamically adjust the spraying state and / or the vector spray gun to extend and retract.

[0013] The technical solution has been further optimized, and the explosive spraying device includes:

[0014] The explosive spraying device body has one end closed and the other end open and connected to the vector spray gun.

[0015] A powder feeding system is connected to the powder input end of the explosive spraying device body and is used to feed powder into the explosive spraying device body.

[0016] An oxidant delivery system is provided, which is connected to the oxidant input end of the explosive spraying device body and is used to input oxidant into the explosive spraying device body.

[0017] A fuel delivery system, which is connected to the fuel input end of the explosive spraying device body and is used to input fuel into the explosive spraying device body;

[0018] An igniter is disposed on the side wall of the explosive spraying device body and is used to ignite the mixed gas inside the explosive spraying device body.

[0019] To further optimize the technical solution, the explosive spraying device also includes:

[0020] A cooling system is provided along the outer wall of the explosive spraying device body and is used to reduce the temperature of the outer wall of the explosive spraying device body by means of an input cooling medium.

[0021] To further optimize the technical solution, the outlet of the vector spray gun is circular, and the outlet area of ​​the vector spray gun is equal to the cross-sectional area of ​​the explosive spraying device body when it is at its maximum.

[0022] The shrinkage ratio of the vector spray gun is less than or equal to 2.

[0023] The technical solution has been further optimized, and the data acquisition system includes:

[0024] A pressure sensor is inserted into the body of the explosive spraying device and is used to measure the pressure of the detonation wave inside the body of the explosive spraying device in real time.

[0025] A thermocouple, which is in contact with the outer wall surface of the explosive spraying device body and is used to measure the temperature of the outer wall surface of the explosive spraying device body;

[0026] A signal acquisition device is used to receive signals transmitted by the pressure sensor and the thermocouple, and the output terminal of the signal acquisition device is connected to the input terminal of the control system.

[0027] To further optimize the technical solution, the data acquisition system also includes:

[0028] The particle state monitor is used to monitor the temperature, velocity and spray width of the powder after it is emitted from the vector spray gun in real time, and can also monitor the surface temperature of the workpiece to be sprayed and the perpendicularity of the workpiece to be sprayed to the central axis of the explosive spraying device.

[0029] To further optimize the technical solution, the particle state monitor has a higher priority than the signal acquisition instrument.

[0030] To further optimize the technical solution, at least two pressure sensors are provided, and each pressure sensor is evenly spaced along the axial direction of the explosive spraying device body; the detection information of two adjacent pressure sensors is used to determine whether the mixed gas is properly detonated.

[0031] The control system further optimizes the technical solution and includes:

[0032] The control cabinet, wherein the output terminal of the acquisition system is connected to the input terminal of the control cabinet;

[0033] The computer is capable of displaying information on various parameters to be monitored in real time, and the computer is interactively connected to the control cabinet.

[0034] A powder flow control valve is installed on the powder feeding system, and the controlled end of the powder flow control valve is connected to the output end of the control cabinet.

[0035] An oxidant flow control valve is installed on the oxidant delivery system, and the controlled end of the oxidant flow control valve is connected to the output end of the control cabinet.

[0036] A fuel flow control valve is installed on the fuel delivery system, and the controlled end of the fuel flow control valve is connected to the output end of the control cabinet.

[0037] Further optimization of the technical solution also includes a position adjustment system, which comprises:

[0038] The robotic arm is fixed to the explosive spraying device body. The robotic arm can drive the explosive spraying device body to rotate and move in all directions in three-dimensional space. The controlled end of the robotic arm is connected to the output end of the control cabinet.

[0039] and / or a stage, the stage being used to fix the workpiece to be sprayed and being able to rotate 360 ​​degrees on a horizontal reference, the controlled end of the stage being connected to the output end of the control cabinet.

[0040] An intelligent explosive spraying control method, the method controlling an intelligent explosive spraying system, includes the following steps:

[0041] S1. Before performing explosive spraying, obtain the structural information of the workpiece to be sprayed, and divide the workpiece to be sprayed into several areas to be sprayed in sequence.

[0042] The structural information of the workpiece to be coated and the information of the divided areas to be coated are imported into the control system;

[0043] S2. Based on the coating requirements of each area to be sprayed, input the spraying parameters and the set values ​​of each monitored parameter into the control system;

[0044] S3. The control system controls the explosive spraying device to spray an area to be sprayed;

[0045] The data acquisition system collects real-time data on the spraying process of the explosive spraying device and the status of the workpiece to be sprayed, and transmits the collected information to the control system.

[0046] S4. The control system compares and calculates the information collected by the acquisition system with the set value of the parameter to be monitored, and outputs instructions according to the calculation results to control the explosive spraying device to dynamically adjust the spraying state and / or the vector spray gun to extend and retract.

[0047] S5. Complete the spraying of one area to be sprayed;

[0048] S6. Repeat steps S3 to S5 to spray the remaining areas to be sprayed.

[0049] Further optimize the technical solution. The set values ​​of each parameter to be monitored include one or more of the following: the lower limit of the average propagation speed of the detonation wave, the lower limit of the detonation wave pressure, the upper limit of the temperature of the outer wall of the explosive spraying device, the lower limit of the temperature of the sprayed powder after it is transmitted from the vector spray gun, the lower limit of the flight speed, the upper limit of the spray beam width, the upper limit of the surface temperature of the workpiece to be sprayed, the upper limit of the angle between the workpiece to be sprayed and the central axis of the explosive spraying device, or the lower limit of the angle between the workpiece to be sprayed and the central axis of the explosive spraying device.

[0050] To further optimize the technical solution, before proceeding to step S3, pre-ignition and pre-spraying tests are conducted on each area to be sprayed.

[0051] The technical solution is further optimized by automatically adjusting the spraying efficiency based on the complexity of the area to be sprayed.

[0052] When the area to be sprayed has a simple structure and a regular surface, increase the flow rate of fuel, oxidant, powder and carrier gas, increase the ignition frequency of the igniter, and increase the moving speed of the robotic arm and the platform to shorten the spraying time and improve the spraying efficiency.

[0053] When the area to be sprayed has a complex structure and varied dimensions, the flow rates of fuel, oxidant, powder and carrier gas should be reduced, the ignition frequency of the igniter should be reduced, the moving speed of the robotic arm and the platform should be reduced, and the vector spray gun should be retracted to reduce the size of the circular spot formed by a single spray, so as to improve the spraying accuracy and thus improve the coating quality.

[0054] The technical solution of this invention has the following advantages:

[0055] 1. The present invention provides an intelligent explosive spraying system that combines a data acquisition system with a control system to adjust the spraying process based on the spraying process of the explosive spraying device and the condition of the workpiece to be sprayed. It monitors and dynamically adjusts the spraying process in real time, giving the explosive spraying system active control and self-adjustment functions, which significantly improves the flexibility, practicality, spraying efficiency and coating quality of the explosive spraying system.

[0056] 2. The present invention provides an intelligent explosive spraying system in which a cooling system is arranged along the outer wall of the explosive spraying device body. The system reduces the temperature of the outer wall of the explosive spraying device body by inputting a cooling medium, thereby preventing continuous combustion.

[0057] 3. The present invention provides an intelligent explosive spraying system in which the shrinkage ratio is less than or equal to 2 when the vector spray gun shrinks, so as to avoid the flow field formed by the pressure oscillation inside the pipe when the shrinkage ratio is too large, which would cause the detonation wave to fail.

[0058] 4. The present invention provides an intelligent explosive spraying system in which the vector spray gun can contract and expand in real time according to the surface shape of the current spraying area. When the explosive spraying device is spraying an area with high surface curvature, the vector spray gun contracts; when the surface of the spraying area gradually transitions to a flatter shape, the vector spray gun gradually expands. By contracting and expanding the vector spray gun in a two-dimensional scale, the size of the circular spot formed by powder deposition on the surface of the workpiece after each spray is changed, thereby achieving adjustment of the spraying process.

[0059] 5. The present invention provides an intelligent explosive spraying system, wherein at least two pressure sensors are provided, and each pressure sensor is evenly spaced along the axial direction of the explosive spraying device body. The detection information of two adjacent pressure sensors is used to determine whether the mixed gas is normally detonated.

[0060] 6. The intelligent detonation spraying system provided by this invention prioritizes the particle state monitor over the signal acquisition device. When the signal acquisition device indicates insufficient detonation wave velocity or low detonation wave pressure, but the powder parameters monitored by the particle state monitor meet the set values, the control system will not adjust the spraying parameters.

[0061] 7. The present invention provides an intelligent explosive spraying control method, which can adopt different spraying control methods based on the specific structure and surface condition of the workpiece to be sprayed and the working environment of different areas to be sprayed in the workpiece, thereby optimizing the spraying process, improving both spraying efficiency and coating quality.

[0062] 8. The present invention provides an intelligent explosive spraying control method that can compare and calculate the monitored values ​​and set values ​​of various parameters in real time. When a parameter exceeds the limit, the control system will output instructions to adjust the spraying parameters such as the flow rate of fuel, oxidant, powder and carrier gas, ignition frequency, as well as the rotation angle and moving speed of the robotic arm and platform, so that the parameters exceeding the limit are restored to normal levels, thus ensuring the spraying effect. Attached Figure Description

[0063] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0064] Figure 1 This is a schematic diagram of the structure of an intelligent explosive spraying system according to the present invention;

[0065] Figure 2 This is a schematic diagram of the workpiece to be coated according to the present invention;

[0066] Figure 3 This is a top view of the workpiece to be coated and a schematic diagram of the area to be coated according to the present invention.

[0067] Figure label:

[0068] 1. Explosive spraying device; 2. Vector spray gun; 3. Workpiece to be sprayed; 4. Powder flow control valve; 5. Oxidant flow control valve; 6. Fuel flow control valve; 7. Cooling water flow control valve; 8. Robotic arm; 9. Pressure sensor; 10. Thermocouple; 11. Computer; 12. Signal acquisition instrument; 13. Particle state monitor; 14. All-in-one computer; 15. Control cabinet; 16. Powder feeder; 17. Carrier gas cylinder; 18. Powder feeding pipeline; 19. Oxidant pipeline; 20. Fuel pipeline; 21. Cooling water pipeline; 22. Ignition device; 23. Platform; 24. Area to be sprayed I; 25. Area to be sprayed II; 26. Area to be sprayed III; 27. Area to be sprayed IV. Detailed Implementation

[0069] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0070] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0071] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0072] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0073] Example 1

[0074] like Figure 1 As shown in the figure, this embodiment discloses an intelligent explosive spraying system, including an explosive spraying device 1, a vector spray gun 2, a data acquisition system, and a control system.

[0075] The explosive spraying device 1 is used to input fuel, oxidant, and powder, and generates a high-temperature and high-pressure gas flow when ignited, causing the powder to bombard the surface of the workpiece 3 to be sprayed to form a coating.

[0076] The vector spray gun 2 is positioned at the powder outlet end of the explosive spraying device 1, coaxially with the device, and adaptively expands and contracts according to the structural information of the workpiece 3 to be sprayed. The vector spray gun 2 can contract and expand in a two-dimensional scale to change the size of the circular spots formed by powder deposition on the surface of the workpiece 3 after each spray.

[0077] The data acquisition system is used to collect data in real time on the spraying process of the explosive spraying device 1 and the status of the workpiece 3 to be sprayed.

[0078] The control system is used to receive signals transmitted by the acquisition system and control the explosive spraying device 1 to dynamically adjust the spraying state and / or the vector spray gun 2 to extend and retract.

[0079] The aforementioned intelligent explosive spraying system utilizes a combination of a data acquisition system and a control system to adjust the spraying process based on the spraying process of the explosive spraying device 1 and the condition of the workpiece to be sprayed. It monitors and dynamically adjusts the spraying process in real time, enabling the explosive spraying system to have active control and self-adjustment functions, significantly improving the flexibility, practicality, spraying efficiency, and coating quality of the explosive spraying system.

[0080] The explosive spraying device 1 includes an explosive spraying device body, a powder feeding system, an oxidizer delivery system, a fuel delivery system, and an igniter 22. The explosive spraying device body is a circular tube, with one end closed and the other end open and connected to a vector spray gun 2. The powder feeding system is connected to the powder input end of the explosive spraying device body and is used to feed powder into the explosive spraying device body. The oxidizer delivery system is connected to the oxidizer input end of the explosive spraying device body and is used to feed oxidizer into the explosive spraying device body. The fuel delivery system is connected to the fuel input end of the explosive spraying device body and is used to feed fuel into the explosive spraying device body. The igniter 22 is located on the side wall of the explosive spraying device body and is used to ignite the fresh gas mixture inside the explosive spraying device body.

[0081] When the above-mentioned explosive spraying device 1 is in use, powder, fuel and oxidant can be directly fed into the body of the explosive spraying device for mixing. Under the action of igniter 22, the fresh mixed gas is ignited, so that detonation wave and high temperature and high pressure gas are generated in the explosive spraying device 1, thereby melting the powder.

[0082] The powder feeding system includes a powder feeder 16, a carrier gas cylinder 17, and a powder feeding pipeline 18. The powder feeding pipeline 18 is connected to the closed end of the explosive spraying device body and communicates with the interior of the explosive spraying device body. The powder feeder 16 is mounted on the powder feeding pipeline 18 and contains powder. The carrier gas cylinder 17 is connected to the powder feeder 16 via a carrier gas delivery pipe, and the carrier gas cylinder 17 can output gas, thereby pushing the powder inside the powder feeder 16 through the powder feeding pipeline 18 into the explosive spraying device body. In this embodiment, the controlled end of the powder feeder 16 is connected to the output end of the control system, thereby adjusting the powder feeding amount by controlling the operating conditions of the powder feeder 16. The powder feeding system in this embodiment can change the powder flow rate and carrier gas flow rate in real time.

[0083] The carrier gas in carrier gas cylinder 17 can be compressed air or nitrogen, and the selection must be made in computer 11 before use. When using compressed air, the oxygen content should be included in the oxidizer required for combustion. When using nitrogen, since the volume inside the explosive spraying device is fixed, the addition of nitrogen dilutes the proportion of the combustible mixture and affects the collision probability of activated molecules, making the mixture difficult to ignite. Therefore, its dilution effect should be considered.

[0084] The oxidant delivery system includes an oxidant line 19 and an oxidant source. One end of the oxidant line 19 is connected to the interior of the explosive spraying apparatus, and the other end is connected to the oxidant source. The oxidant line 19 is used to deliver the oxidant into the explosive spraying apparatus.

[0085] The fuel delivery system includes a fuel line 20 and a fuel source. One end of the fuel line 20 is connected to the interior of the explosive spraying apparatus, and the other end is connected to the fuel source. The fuel line 20 is used to deliver fuel into the explosive spraying apparatus.

[0086] As a further improved embodiment, the explosive spraying apparatus 1 also includes a cooling system. The cooling system is arranged along the outer wall of the explosive spraying apparatus body and is used to reduce the temperature of the outer wall of the explosive spraying apparatus body by means of an input cooling medium. The cooling medium can be cooling water or other media. When cooling water is used as the cooling medium, the cooling system specifically includes a cooling water pipe 21 and a cooling water source. The cooling water pipe 21 is located around the outer wall of the explosive spraying apparatus body, with one end connected to the cooling water source and the other end outputting the cooled water after heat exchange. The cooling water pipe 21 is used to transport cooling water to the outer wall of the explosive spraying apparatus body to reduce its wall temperature and prevent continuous combustion.

[0087] As a further improved implementation, the outlet of the vector spray gun 2 is circular, and the outlet area of ​​the vector spray gun 2 is equal to the cross-sectional area of ​​the explosive spraying device body when it is at its maximum. When the vector spray gun 2 contracts, the contraction ratio is less than or equal to 2, to avoid the flow field formed by pressure oscillation inside the tube when the contraction ratio is too large, which would cause the detonation wave to fail.

[0088] As a further improved implementation, the vector spray gun 2 can contract and expand in real time according to the surface shape of the current spraying area. The vector spray gun 2 can change its exit area by performing a series of linked actions through the actuation mechanism and linkage structure. When the explosive spraying device 1 is spraying an area with high surface curvature, the vector spray gun 2 contracts; when the surface of the spraying area gradually transitions to a flatter shape, the vector spray gun 2 gradually expands.

[0089] The automatic contraction and expansion principle of the vector spray gun: After importing the specific structure, shape, size, or 3D model of the workpiece to be sprayed into the computer and dividing the area to be sprayed, this invention can accurately identify the structure, shape, and size contained in each area to be sprayed, and automatically adjust the spraying parameters according to different structures, shapes, and sizes. Specifically, for the vector spray gun, when the area to be sprayed is an arc-shaped protrusion, the curvature is high at the protrusion and gradually decreases downwards. Therefore, it is obviously unsuitable for the vector spray gun's outlet to remain constant. If the vector spray gun's outlet is always at its maximum, and the central axis of the outlet is perpendicular to the surface to be sprayed (generally, perpendicularity is required, meaning the particles impact the workpiece surface perpendicularly), then when spraying the protrusion, the size of the circular spot formed by a single spray is very large. This may result in the central area of ​​the circular spot being sprayed on the protrusion, while the area outside the center is sprayed on the wall surface downwards along the protrusion. The particle flight direction is not perpendicular to the wall surface downwards along the protrusion, which will seriously reduce the coating quality. Therefore, the correct approach is to automatically reduce the size of the vector spray gun, making its exit point smaller. This results in a smaller circular spot formed by a single spray, allowing all particles to be deposited on the protrusions and improving coating quality.

[0090] The control system includes a control cabinet 15, a computer 11, a powder flow control valve 4, an oxidant flow control valve 5, and a fuel flow control valve 6. The output of the data acquisition system is connected to the input of the control cabinet 15. The computer 11 can display information on various monitored parameters in real time, such as detonation wave pressure and the outer wall temperature of the explosive spraying device 1. The computer 11 is interactively connected to the control cabinet 15, allowing manual input of commands. The control cabinet 15 receives signals, performs real-time calculations in its internal CPU, and outputs control commands. The powder flow control valve 4 is installed on the powder feeding system to regulate the flow of powder and carrier gas; its controlled end is connected to the output of the control cabinet 15. The oxidant flow control valve 5 is installed on the oxidant delivery system to regulate the oxidant flow; its controlled end is connected to the output of the control cabinet 15. The fuel flow control valve 6 is installed on the fuel delivery system to regulate the fuel flow; its controlled end is connected to the output of the control cabinet 15.

[0091] The control system also includes a cooling water flow control valve 7, which is installed on the cooling water pipeline 21 and is used to regulate the cooling water flow. The controlled end of the cooling water flow control valve 7 is connected to the output end of the control cabinet 15.

[0092] The data acquisition system includes a pressure sensor 9, a thermocouple 10, and a signal acquisition unit 12. The pressure sensor 9 is inserted into the body of the explosive spraying device to measure the pressure of the detonation wave inside the device in real time. The thermocouple 10 is in contact with the outer wall surface of the explosive spraying device to measure the temperature of the outer wall surface. The output of the signal acquisition unit 12 is connected to the input of the control system. The signal acquisition unit 12 receives the signals transmitted by the pressure sensor 9 and the thermocouple 10, converts these signals into electrical signals, and sends them to the control cabinet 15.

[0093] As a further improved implementation, at least two pressure sensors 9 are provided, and each pressure sensor 9 is evenly spaced along the axial direction of the explosive spraying device body. The detection information of each pressure sensor 9 and the detection time interval information of each pressure sensor 9 can also be displayed on the computer 11. The detection information of two adjacent pressure sensors 9 is used to determine whether the gas mixture has been properly detonated. The specific principle is as follows: the propagation time of the detonation wave after passing through two pressure sensors 9 can be obtained. The average propagation speed of the detonation wave can be obtained by dividing the distance between the two pressure sensors 9 by the propagation time. This is used to determine whether the fresh gas mixture has been properly detonated after being ignited. The average propagation speed of the detonation wave is also displayed on the computer 11 and the integrated computer 14.

[0094] As a further improved implementation, the acquisition system also includes a particle state monitor 13. The particle state monitor 13 is used to monitor in real time the temperature, velocity, and spray width of the powder after it exits the vector spray gun 2. It can also monitor the surface temperature of the workpiece 3 to be sprayed and the perpendicularity of the workpiece 3 to the central axis of the explosive spraying device, converting these parameters into electrical signals and transmitting them to the control cabinet 15. These monitored parameters can be displayed in real time on the computer 11. The particle state monitor 13 is also equipped with an integrated computer 14, which can also display the monitored parameters in real time and store the data on a hard disk for subsequent analysis.

[0095] The main purpose of the particle state monitor 13 in this invention is to optimize the coating performance by monitoring parameters such as spraying distance, temperature, and pressure. The kinetic energy and thermal characteristics of powder particles determine the quality of the coating, and the most important particle parameters are: size, shape, density, velocity, and temperature.

[0096] It should be noted that, strictly speaking, a particle state monitor is not a single device, but rather a small system, primarily consisting of a computer, a high-speed camera, a laser emitter (when needed), lenses, and a test stand. These components can also be integrated into a single unit for a simpler design.

[0097] The working principle of the particle state monitor is as follows: The basic measurement method of the particle state monitor is based on particle illumination. During thermal spraying, the particles are in a molten state and emit visible radiation. Illumination and related optical signal detection and analysis mechanisms are not required. It is a diagnostic system based on optical imaging, capable of measuring the most important particle properties and obtaining images of the spraying process. The particle state monitor can measure particle temperature using a pyrometer based on the particle's self-emission effect, and can also use an optical temperature measurement system to measure particle temperature. It is also applicable to the surface temperature of the workpiece 3 to be sprayed. Under the assumption of spherical particles, the particle diameter can be recalculated based on Planck's radiation and surface law. The spray width and particle velocity can be obtained through optical imaging combined with computer calculations. The perpendicularity of the workpiece 3 to be sprayed to the central axis of the explosive spraying device 1 can be determined by computer analysis based on the optical imaging.

[0098] As a further improved implementation, the particle state monitor 13 has a higher priority than the signal acquisition device 12. When the signal acquired by the signal acquisition device 12 indicates that the detonation wave velocity is insufficient or the detonation wave pressure is low, but the powder parameters monitored by the particle state monitor 13 meet the set values, the control system will not adjust the spraying parameters.

[0099] As a further improved embodiment, the present invention also includes a position adjustment system, which includes a robotic arm 8 and / or a stage 23. The explosive spraying device body is fixed to the robotic arm 8, which is capable of rotating and moving the explosive spraying device body in all directions in three-dimensional space. The controlled end of the robotic arm 8 is connected to the output end of the control cabinet 15. The stage 23 is used to fix the workpiece 3 to be sprayed and is capable of rotating 360 degrees on a horizontal reference. The controlled end of the stage 23 is connected to the output end of the control cabinet 15.

[0100] Example 2

[0101] This embodiment discloses an intelligent explosive spraying control method, which controls an intelligent explosive spraying system as described in Embodiment 1, and includes the following steps:

[0102] S1. Before performing explosive spraying, the structural information of the workpiece 3 to be sprayed is obtained through a scanning tool, and the data is imported into the computer 11. After manual analysis and processing, it is divided into several areas to be sprayed in sequence. For example... Figure 2 , Figure 3 As shown, in this embodiment, the workpiece 3 to be sprayed is divided into spraying area I 24, spraying area II 25, spraying area III 26, and spraying area IV 27.

[0103] The method for dividing the area to be sprayed can be based on the complexity of the actual spraying, following either an easy-to-difficult or difficult-to-easy order. In this case, it is divided into an easy-to-difficult order. The structural information of the workpiece 3 to be sprayed includes its external shape and structure.

[0104] The information of the workpiece 3 to be sprayed and the divided areas to be sprayed is imported into the control cabinet 15 in the control system. The control cabinet 15 formulates the spraying plan according to the different structural information of the workpiece 3 to be sprayed.

[0105] Before spraying, according to the spraying plan, the control cabinet 15 sends control commands to the robotic arm 8 and / or the platform 23 to adjust the three-dimensional coordinates of the explosive spraying device. The specific adjustment method is as follows: the control cabinet 15 adjusts and controls the relative position of the robotic arm 8 and / or the platform 23 to establish three-dimensional coordinates and base points, so as to control the explosive spraying device 1 to spray each area to be sprayed in sequence.

[0106] S2. Before the explosive spraying, according to the coating requirements of each area to be sprayed, the spraying parameters and the set values ​​of each monitoring parameter are input into the control cabinet 15 through the computer 11 for comparison and calculation with the real-time collected values.

[0107] Considering that the surface shape of each area to be sprayed in the workpiece 3 is different, it is impractical to use the same spraying parameters for each area. Therefore, the computer 11 should be used to set the spraying parameters for the four different areas to be sprayed. For example, the surface of area I 24 to be sprayed is smooth and the spraying difficulty is low. The flow rates of fuel, oxidant, powder and carrier gas can be increased, the ignition frequency can be increased, and the movement and rotation speed of the robotic arm 8 and the platform 23 can be increased, thereby improving the spraying efficiency and saving time. On the other hand, the surface of area IV 27 to be sprayed is raised and the spraying difficulty is high. The above spraying parameters can be appropriately reduced, and the vector spray gun 2 can be retracted to reduce the area of ​​the circular spot formed by each spray, making the spraying work more refined and improving the coating quality.

[0108] Furthermore, considering that the working conditions of each area to be coated may differ after the workpiece 3 is put into production, setting the same monitoring parameter settings for each area is not practical. Therefore, the monitoring parameter settings for four different areas to be coated should be set separately by computer 11. For example, in areas with harsh working environments, the lower limit of the average propagation velocity of the detonation wave, the lower limit of the detonation wave pressure, the lower limit of the temperature of the sprayed powder after it leaves the vector spray gun 2, and the lower limit of the flight speed can be appropriately increased, while the upper limit of the spray beam width can be appropriately decreased, etc., to improve the coating quality and extend the service life of the workpiece 3.

[0109] Once all the above parameters are set, they are transmitted to control cabinet 15 for comparison, calculation, dynamic adjustment of spraying parameters, and optimization of the spraying process.

[0110] The set values ​​for each monitored parameter include one or more of the following: the lower limit of the average propagation velocity of the detonation wave, the lower limit of the detonation wave pressure, the upper limit of the outer wall temperature of the explosive spraying device 1, the lower limit of the temperature of the sprayed powder after it exits the vector spray gun 2, the lower limit of the flight velocity, the upper limit of the spray beam width, the upper limit of the surface temperature of the workpiece 3 to be sprayed, and the upper limit or lower limit of the angle between the workpiece 3 to be sprayed and the central axis of the explosive spraying device 1. Furthermore, these set values ​​change with the current operating conditions of the explosive spraying; that is, the set value under a certain operating condition is a point on a curve formed by coupling the set values ​​under all operating conditions.

[0111] S3. Start explosive spraying. The control system controls the explosive spraying device 1 to spray an area to be sprayed.

[0112] Based on the settings in steps S1 and S2, the area to be sprayed, I24, is first sprayed. This area has a smooth surface and consists of three planes. After the explosive spraying system identifies the area to be sprayed, I24, the explosive spraying device 1 supplies gas and ignites it, starting from the base point. Then, powder is introduced to begin spraying. With the coordinated operation of the robotic arm 8 and the platform 23, the explosive spraying device 1 can sequentially spray each plane until the spraying of the area to be sprayed, I24, is completed. Since the surface of the area to be sprayed is smooth and consists of three planes, the spraying difficulty is relatively low. Therefore, according to the settings in steps S1 and S2, the control cabinet 15 can output commands to increase the flow rate of fuel, oxidant, powder, and carrier gas, increase the ignition frequency, and simultaneously increase the movement and rotation speed of the robotic arm 8 and the platform 23, thereby improving spraying efficiency and saving time.

[0113] During the spraying process, the data acquisition system collects real-time data on the spraying process of the explosive spraying device 1 and the status of the workpiece 3 to be sprayed, and transmits the collected information to the control cabinet 15 in the control system for analysis and calculation.

[0114] The collected information includes, but is not limited to, the average propagation speed of the detonation wave, the detonation wave pressure, the outer wall temperature of the explosive spraying device 1, the temperature, speed and spray width of the sprayed powder after it is transmitted from the vector spray gun 2, and the surface temperature of the workpiece 3 to be sprayed and its perpendicularity to the central axis of the explosive spraying device 1.

[0115] S4. The CPU in the control cabinet 15 compares and calculates the information collected by the acquisition system with the set values ​​of the parameters to be monitored in real time. Based on the calculation results, it outputs commands to control the explosive spraying device 1 to dynamically adjust the spraying state and / or the vector spray gun 2 to adjust its extension and retraction. The control cabinet 15 outputs commands to dynamically adjust the explosive spraying process so that the quality of the prepared coating meets the usage requirements. More specifically, it controls the spraying parameters such as the opening degree of the powder flow control valve 4, oxidant flow control valve 5, fuel flow control valve 6, and cooling water flow control valve 7, as well as the retraction degree of the vector spray gun 2, the ignition frequency of the igniter 22, the movement and rotation orientation of the robotic arm 8, the powder flow rate and carrier gas flow rate of the powder feeder 16, and the rotation angle parameters of the stage 23, in order to control and optimize the explosive spraying process and improve the coating quality.

[0116] For example, when the speed and temperature of the powder after it leaves the vector spray gun 2 are lower than the set value, the control system will output a command to automatically increase the proportion of fuel in the combustible mixture or decrease the proportion of oxidizer, so as to increase the equivalence ratio, thereby increasing the speed of the detonation wave and the temperature of the gas, and thus increasing the speed and temperature of the powder after it leaves the vector spray gun 2. At this time, the temperature of the outer wall surface of the explosion spraying device 1 will also rise, and the control system will automatically increase the cooling water flow rate to maintain the wall temperature and avoid continuous combustion.

[0117] S5. Complete the spraying of one area to be sprayed.

[0118] S6. Repeat steps S3 to S5 to spray the remaining areas to be sprayed.

[0119] For example, when the spraying of area I24 is completed, the explosive spraying device 1 stops supplying gas and igniting, and the robotic arm 8 repositions it to the base point of area II25 to be sprayed, and performs a complete spraying of this area. This area has a concave surface, a planar structure on both sides, and a smaller size, making it more difficult to spray than area I24. Therefore, according to the settings in steps S1 and S2, the control cabinet 15 can output commands to appropriately reduce the flow rates of fuel, oxidizer, powder, and carrier gas, reduce the ignition frequency, and simultaneously reduce the movement and rotation speed of the robotic arm 8 and the stage 23, shrink the vector spray gun 2, and reduce the size of the circular spot formed by a single spray, thereby improving the coating quality while ensuring spraying efficiency. During the spraying process, similar to step S4, the control system also monitors and dynamically adjusts the explosive spraying process in real time to ensure the spraying effect.

[0120] Repeat the spraying process until all areas to be sprayed are completed. Then, turn off the powder feeder 16, stop the supply of fuel, oxidizer, and cooling water, and turn off the igniter 22. Finally, reset the explosion spraying device 1.

[0121] In the above steps, steps S1 and S2 enable the explosive spraying system to have an active control function, which can spray the workpiece sequentially based on the set parameters; during the spraying process in steps S3-S6, the explosive spraying system has a self-adjustment function. When the monitored parameters deviate from the normal range, the control system can dynamically adjust the spraying parameters to restore the monitored parameters to the normal level.

[0122] During the spraying process, the vector spray gun 2 can automatically contract and expand in real time according to the surface shape of the current spraying area. For example, the surface shape of the area to be sprayed, Ⅲ26, is partly flat and partly curved. When the explosive spraying device 1 is spraying a curved surface with a high curvature, the vector spray gun 2 contracts and the spraying parameters are appropriately reduced to avoid clogging when the outlet area becomes smaller and the flow rate remains unchanged. When the spraying area gradually transitions to a flat surface, the vector spray gun 2 gradually expands and the spraying parameters are gradually increased to improve the spraying efficiency and coating quality.

[0123] As a further improved implementation, during the spraying process, when the temperature of the outer wall surface of the explosion spraying device 1 monitored by the thermocouple 10 is transmitted to the control cabinet 15 and, after analysis and calculation, shows an over-temperature condition, the control cabinet 15 will issue a command to increase the opening of the cooling water flow control valve 7 and increase the cooling water flow to remove more heat and keep the heat load of the outer wall surface of the explosion spraying device 1 at a normal level.

[0124] All monitoring parameters and spraying parameters during the spraying process are displayed in real time on computer 11 and all-in-one computer 14. After spraying is completed, the spraying data can be downloaded to the storage hard drive of all-in-one computer 14 for subsequent analysis. During the spraying process, computer 11 can be manually controlled to temporarily stop or terminate the spraying work.

[0125] As a further improved implementation, to ensure coating quality before step S3, pre-ignition and pre-spraying are required before formal spraying. Based on the actual conditions of the area to be sprayed, spraying parameters, and the set values ​​of the parameters to be monitored, the powder flow control valve 4, oxidizer flow control valve 5, and fuel flow control valve 6 are controlled to adjust the flow ratio of fuel, oxidizer, and carrier gas to near the equivalence ratio. When the carrier gas is compressed air, the influence of its oxygen content on combustion should be considered; when the carrier gas is nitrogen, its dilution effect should be considered. After the mixed gas enters the explosive spraying device 1, it is ignited by the igniter 22 to form slow combustion, which then gradually develops into deflagration combustion, ultimately transitioning from deflagration to detonation to form a detonation wave that propagates self-sustainingly along the direction of the fresh mixed gas. During the pre-ignition stage, the main focus is on the propagation speed and pressure of the detonation wave. Once these requirements are met, the powder feeder 16 can be controlled to adjust the powder quantity and introduce it into the carrier gas for pre-spraying. During the pre-spraying stage, the temperature, velocity, and spray width of the powder after it exits the vector spray gun 2 should be closely monitored. Once these requirements are met, the next stage can begin. Since the spraying conditions for the four areas to be sprayed may differ, pre-ignition and pre-spraying tests must be conducted under all four conditions. Before each pre-spraying and formal spraying, combustion gas must be supplied first, followed by powder introduction. When shutting down the system after spraying, the powder supply should be stopped first, followed by the supply of fuel and oxidizer. The workpiece 3 to be sprayed should be removed during pre-ignition and pre-spraying.

[0126] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. An intelligent explosive spraying system, comprising: Explosive spraying device (1), the explosive spraying device (1) is used to input fuel, oxidant and powder, and generate high temperature and high pressure airflow when ignited so that the powder bombards the surface of the workpiece (3) to be sprayed to form a coating. Its characteristic is that it further includes: Vector spray gun (2), the vector spray gun (2) is set at the powder outlet end of the explosive spraying device (1), and adaptively expands and contracts according to the structural information of the workpiece (3) to be sprayed; the vector spray gun (2) contracts and expands in real time according to the surface shape of the current spraying area, and the vector spray gun (2) changes its outlet area by performing a series of actions through the actuation mechanism and linkage structure; when the explosive spraying device (1) is spraying an area with high surface curvature, the vector spray gun (2) contracts, and when the surface of the spraying area gradually transitions to a flatter surface, the vector spray gun (2) also gradually expands; when the outlet area of ​​the vector spray gun (2) is at its maximum, it is equal to the cross-sectional area of ​​the explosive spraying device body; the contraction ratio of the vector spray gun (2) is less than or equal to 2; The data acquisition system is used to collect data in real time on the spraying process of the explosive spraying device (1) and the status of the workpiece (3) to be sprayed. The control system is used to receive signals transmitted by the acquisition system and control the explosive spraying device (1) to perform dynamic adjustment of the spraying state and / or the vector spray gun (2) to perform telescopic adjustment.

2. The intelligent explosive spraying system according to claim 1, characterized in that, The explosive spraying device (1) includes: The explosive spraying device body has one end closed and the other end open and connected to the vector spray gun (2). A powder feeding system is connected to the powder input end of the explosive spraying device body and is used to feed powder into the explosive spraying device body. An oxidant delivery system is provided, which is connected to the oxidant input end of the explosive spraying device body and is used to input oxidant into the explosive spraying device body. A fuel delivery system, which is connected to the fuel input end of the explosive spraying device body and is used to input fuel into the explosive spraying device body; Ignition device (22), which is disposed on the side wall of the explosive spraying device body and is used to ignite the mixed gas inside the explosive spraying device body.

3. The intelligent explosive spraying system according to claim 2, characterized in that, The explosive spraying device (1) also includes: A cooling system is provided along the outer wall of the explosive spraying device body and is used to reduce the temperature of the outer wall of the explosive spraying device body by means of an input cooling medium.

4. An intelligent explosive spraying system according to claim 2 or 3, characterized in that, The outlet of the vector spray gun (2) is circular, and when the outlet area of ​​the vector spray gun (2) is at its maximum, it is equal to the cross-sectional area of ​​the explosive spraying device body. The shrinkage ratio of the vector spray gun (2) is less than or equal to 2.

5. The intelligent explosive spraying system according to claim 2, characterized in that, The data acquisition system includes: Pressure sensor (9), the pressure sensor (9) is inserted into the body of the explosive spraying device and is used to measure the pressure of the detonation wave inside the body of the explosive spraying device in real time; Thermocouple (10) is in contact with the outer wall surface of the explosive spraying device body and is used to measure the temperature of the outer wall surface of the explosive spraying device body. The signal acquisition device (12) is used to receive the signals transmitted by the pressure sensor (9) and the thermocouple (10). The output end of the signal acquisition device (12) is connected to the input end of the control system.

6. The intelligent explosive spraying system according to claim 5, characterized in that, The data acquisition system also includes: The particle state monitor (13) is used to monitor the temperature, speed and spray width of the powder after it is transmitted from the vector spray gun (2) in real time, and can monitor the surface temperature of the workpiece (3) to be sprayed and the perpendicularity of the workpiece (3) to the central axis of the explosive spraying device.

7. The intelligent explosive spraying system according to claim 6, characterized in that, The particle state monitor (13) has a higher priority than the signal acquisition device (12).

8. The intelligent explosive spraying system according to claim 5, characterized in that, At least two pressure sensors (9) are provided, and each pressure sensor (9) is evenly spaced along the axial direction of the explosive spraying device body; the detection information of two adjacent pressure sensors (9) is used to determine whether the mixed gas is normally detonated.

9. The intelligent explosive spraying system according to claim 2, characterized in that, The control system includes: Control cabinet (15), the output end of the acquisition system is connected to the input end of the control cabinet (15); Computer (11), which can display various collected parameter information in real time, and computer (11) is interactively connected to control cabinet (15); Powder flow control valve (4), the powder flow control valve (4) is installed on the powder feeding system, and the controlled end of the powder flow control valve (4) is connected to the output end of the control cabinet (15); Oxidizing agent flow control valve (5), the oxidizing agent flow control valve (5) is installed on the oxidizing agent delivery system, and the controlled end of the oxidizing agent flow control valve (5) is connected to the output end of the control cabinet (15); A fuel flow control valve (6) is installed on the fuel delivery system, and the controlled end of the fuel flow control valve (6) is connected to the output end of the control cabinet (15).

10. The intelligent explosive spraying system according to claim 9, characterized in that, It also includes a position adjustment system, the position adjustment system comprising: The robotic arm (8) is fixed on the explosive spraying device body. The robotic arm (8) can drive the explosive spraying device body to rotate and move in all directions in three-dimensional space. The controlled end of the robotic arm (8) is connected to the output end of the control cabinet (15). and / or a stage (23), which is used to fix the workpiece (3) to be sprayed and can rotate 360 ​​degrees on a horizontal reference, and the controlled end of the stage (23) is connected to the output end of the control cabinet (15).

11. An intelligent explosive spraying control method, characterized in that, The method describes controlling the intelligent explosive spraying system according to any one of claims 1 to 10, and includes the following steps: S1. Before performing explosive spraying, obtain the structural information of the workpiece (3) to be sprayed, and divide the workpiece (3) to be sprayed into several spraying areas in sequence. The structural information of the workpiece (3) to be sprayed and the information of the divided areas to be sprayed are imported into the control system; S2. Based on the coating requirements of each area to be sprayed, input the spraying parameters and the set values ​​of each monitored parameter into the control system; S3. The control system controls the explosive spraying device (1) to spray an area to be sprayed; The data acquisition system collects the spraying process of the explosive spraying device (1) and the status of the workpiece (3) to be sprayed in real time, and transmits the collected information to the control system. S4. The control system compares and calculates the collected information from the acquisition system with the set value of the parameter to be monitored, and outputs instructions according to the calculation results to control the explosive spraying device (1) to make dynamic adjustments to the spraying state and / or the vector spray gun (2) to make extension and retraction adjustments. S5. Complete the spraying of one area to be sprayed; S6. Repeat steps S3 to S5 to spray the remaining areas to be sprayed.

12. The intelligent explosive spraying control method according to claim 11, characterized in that, The set values ​​of each parameter to be monitored include one or more of the following: the lower limit of the average propagation speed of the detonation wave, the lower limit of the detonation wave pressure, the upper limit of the outer wall temperature of the explosive spraying device (1), the lower limit of the temperature of the sprayed powder after it is transmitted from the vector spray gun (2), the lower limit of the flight speed, the upper limit of the spray beam width, the upper limit of the surface temperature of the workpiece (3) to be sprayed, the upper limit of the angle between the workpiece (3) to be sprayed and the central axis of the explosive spraying device (1), or the lower limit of the angle between the workpiece (3) to be sprayed and the central axis of the explosive spraying device (1).

13. The intelligent explosive spraying control method according to claim 11, characterized in that, Before performing step S3, pre-ignition and pre-spraying tests are conducted on each area to be sprayed.

14. The intelligent explosive spraying control method according to claim 11, characterized in that, The method automatically adjusts the spraying efficiency based on the complexity of the area to be sprayed. When the area to be sprayed has a simple structure and a regular surface, increase the flow rate of fuel, oxidant, powder and carrier gas, increase the ignition frequency of the igniter (22), and increase the moving speed of the robotic arm (8) and the platform (23) to shorten the spraying time and improve the spraying efficiency. When the area to be sprayed has a complex structure and varied dimensions, the flow rates of fuel, oxidant, powder and carrier gas are reduced, the ignition frequency of the igniter (22) is reduced, the moving speed of the robotic arm (8) and the platform (23) is reduced, and the vector spray gun (2) is contracted to reduce the size of the circular spot formed by a single spray, so as to improve the spraying accuracy and thus improve the coating quality.

Images