A method for dealing with powder spray gun clogging

Abstract

This invention relates to the field of powder spraying gun clogging technology, specifically to a method for handling powder spraying gun clogging, comprising the following steps: S1: preparing an inner tube for the powder spraying gun with a sleeve-like structure; S2: real-time monitoring of pressure changes and material flow rate within the inner tube; S3: analyzing data using machine learning algorithms to predict whether the powder spraying gun will become clogged; S4: automatically activating a clogging prevention program when the control system predicts that clogging is about to occur; S5: for clogged powder spraying guns, using rapid cooling technology to reduce the gun temperature to a safe operating level; S6: connecting a declogging tool to the tail end of the inner tube of the powder spraying gun and tapping the clogged area until it loosens, then cutting off the clogged area; S7: restoring the flowability of the powder spraying gun. This invention, by integrating IoT and machine learning technologies to achieve real-time monitoring and clogging prediction of powder spraying guns, significantly improves the service life and production continuity of powder spraying guns, while reducing maintenance costs.

Description

Technical Field

[0001] This invention relates to the field of powder spray gun clogging technology, and more particularly to a method for treating powder spray gun clogging. Background Technology

[0002] In modern steelmaking, the pretreatment of molten iron is crucial, directly affecting steelmaking efficiency and finished product quality. In traditional desulfurization, the use of powder injection guns is essential. These guns inject desulfurizing agents into the molten iron to initiate a chemical reaction. However, powder injection guns are prone to clogging during use. This clogging is mainly caused by factors such as fluctuations in material quality, unstable injection parameters, and improper operation. Once clogging occurs, it usually leads to damage to the powder injection gun, which in turn affects desulfurization efficiency and may even require shutdown. This not only reduces production efficiency but also increases production costs.

[0003] Existing solutions typically involve manual intervention, such as replacing the powder spraying gun or using physical methods to remove blockages. These methods are not only labor-intensive but also pose safety risks, especially in high-temperature operating environments. Furthermore, these methods cause significant wear and tear on the equipment and cannot effectively extend the service life of the powder spraying gun. Therefore, there is an urgent need for a method that can monitor and predict powder spraying gun blockages in real time so that preventive measures can be taken in a timely manner to reduce the probability of blockages. At the same time, once a blockage occurs, a safer and more efficient removal method is needed to restore the powder spraying gun to normal operation, reduce production downtime, and lower equipment replacement costs. Summary of the Invention

[0004] To achieve the above objectives, the present invention provides a method for treating powder spray gun clogging.

[0005] A method for dealing with powder spray gun clogging includes the following steps:

[0006] S1: Prepare an inner tube for the powder spraying gun with a sleeve-like form, so that the inner tube can move along the length of the powder spraying gun under the action of external force;

[0007] S2: A pressure and flow rate sensor is installed in the inner tube of the powder spraying gun to monitor the pressure changes and material flow rate in the inner tube in real time, providing data support for the early warning of blockage of the powder spraying gun.

[0008] S3: The IoT-based control system receives sensor data in real time and analyzes the data through machine learning algorithms to predict whether the powder spraying gun is clogged.

[0009] S4: When the control system predicts that a nozzle blockage is about to occur, it automatically initiates the nozzle blockage prevention program, including adjusting the spraying parameters or sending a signal to replace the powder spraying nozzle.

[0010] S5: For clogged powder spraying guns, use rapid cooling technology to reduce the temperature of the powder spraying gun to a safe operating level;

[0011] S6: Connect the unblocking tool to the tail of the inner tube of the powder spray gun, and tap the blocked part until it is loosened, then cut off the blocked part.

[0012] S7: Use an air compressor to purge the inner tube of the powder spraying gun under high pressure to restore the flowability of the powder spraying gun.

[0013] Furthermore, the inner tube has at least one set of guide structures along the length of the powder spraying gun on its outer surface, and the inner surface of the outer tube has a guide rail that cooperates with the guide structures; the movement range of the inner tube is provided with a limiting structure, which provides a predetermined movement space for the movement of the inner tube.

[0014] Furthermore, S2 specifically includes:

[0015] S21: Install a flow rate sensor at the inlet of the inner tube of the powder spraying gun. The flow rate sensor is used to monitor the flow rate of the material in real time. The flow rate sensor is connected to the inner tube by thread fastening or welding to ensure that the sensor can work stably and accurately measure the material flow rate in a high-temperature environment.

[0016] S22: Install a pressure sensor at the junction of the inner and outer tubes of the powder spraying gun. The pressure sensor is used to monitor the pressure changes in the inner tube in real time. The installation of the pressure sensor should ensure that it responds quickly to the pressure changes in the inner tube and that the data transmission is not affected by the high temperature environment.

[0017] S23: Both the flow rate sensor and the pressure sensor are connected to a microprocessor, which performs preliminary processing on the sensor data and sends the processed data to the Internet of Things-based control system via wireless or wired means.

[0018] Furthermore, S3 specifically includes:

[0019] S31: The control system includes an Internet of Things (IoT) interface for receiving data from the flow rate sensor and pressure sensor in the inner tube of the powder spraying gun in real time. The IoT interface uses an industry-standard communication protocol, MQTT or OPC UA.

[0020] S32: The machine learning algorithm is a supervised learning algorithm, specifically using a support vector machine (SVM) to analyze sensor data. In the algorithm, the flow velocity data is set as v(t) and the pressure data is set as p(t), where t represents the time point.

[0021] S33: The data processing unit in the control system first preprocesses the received data, including normalization and noise reduction, so that the data can be adapted to the algorithm processing.

[0022] S34: The preprocessed data is input into the SVM model, which has been trained using historical data to obtain the optimal classification hyperplane. The specific calculation formula is as follows:

[0023] f(x) = wx + b,

[0024] Where w is the normal vector of the hyperplane, x is the input data vector, and b is the bias term used to predict whether the current operating state tends to block the gun.

[0025] S35: The SVM model uses kernel technology to map the input data to a high-dimensional space, where it finds the hyperplane that maximizes the class margin, thereby improving the accuracy of prediction.

[0026] S36: When the SVM model predicts a risk of clogging in the powder spraying gun, the control system automatically triggers a clogging warning. This warning includes the clogging probability and suggested response measures. The formula for calculating the clogging probability is:

[0027] P block =σ(f(x)),

[0028] Where σ is the sigmoid function, used to convert the model output into a blocking probability.

[0029] Furthermore, S4 specifically includes:

[0030] S41: The control system is equipped with an early warning trigger module, which is responsible for receiving the jamming prediction result from step S37 and activating the jamming prevention program when the jamming risk is predicted.

[0031] S42: The early warning trigger module is connected to the operation control unit of the powder spraying gun. The control unit includes a spraying parameter setting function, which can adjust parameters such as spraying pressure, spraying rate and spraying angle of the powder spraying gun.

[0032] S43: When the early warning trigger module receives the gun blockage prediction signal, it first tries to prevent gun blockage by adjusting the injection parameters, including reducing the injection rate, increasing the injection angle, or adjusting the injection pressure, in order to reduce the deposition of material in the powder injection gun.

[0033] S44: The control system evaluates the effect of adjusting the spraying parameters. If the adjusted parameters fail to reduce the probability of gun blockage or the risk of gun blockage still exists, the warning trigger module sends a signal to replace the powder spraying gun.

[0034] S45: The powder spraying gun replacement signal includes visual and audible alarms to ensure that the operator can receive the instruction to replace the powder spraying gun in a timely manner. At the same time, the control system records the usage time and spraying parameters of the powder spraying gun for subsequent maintenance and analysis.

[0035] S46: The control system simultaneously sends a detailed gun blockage warning report to maintenance personnel. The report includes predicted blockage data, current spraying parameters, and recommended replacement time, so that maintenance personnel can prepare and arrange the replacement of the powder spraying gun.

[0036] S47: If the powder spraying gun is not replaced within a certain period of time after the powder spraying gun replacement signal is issued, the control system will activate a level two warning and raise the alarm level to ensure that the replacement of the powder spraying gun is not delayed, thereby avoiding production interruption or equipment damage.

[0037] Furthermore, S5 specifically includes:

[0038] S51: Determine the current temperature and target safe operating temperature of the powder spraying gun. The target safe operating temperature should be lower than the heat distortion temperature of the powder spraying gun material to avoid damage to the powder spraying gun structure.

[0039] S52: Select rapid cooling technology, which uses liquid nitrogen as the cooling medium;

[0040] S53: The cooling medium injection system includes nozzle design and cooling medium supply pipeline. The nozzle can evenly cover the outer surface of the powder spray gun with cooling medium, while the pipeline ensures a continuous supply of cooling medium.

[0041] S54: Before implementing the cooling procedure, ensure that the powder spray gun is safely positioned in the designated cooling area and that the surrounding environment meets safety standards to avoid the risk to the operating environment caused by leakage of cooling medium.

[0042] S55: Activate the cooling medium injection system to cool the powder spraying gun, while monitoring the temperature of the powder spraying gun until it drops to the target safe operating temperature;

[0043] S56: During the cooling process, a temperature sensor is used to monitor the surface temperature of the powder spraying gun in real time to ensure that the cooling effect reaches the expected level and to avoid thermal stress damage to the powder spraying gun material due to excessively rapid cooling.

[0044] S57: After cooling is complete, perform a post-cooling inspection on the powder spray gun to ensure that its temperature is uniform and there is no structural damage.

[0045] Furthermore, in step S6, the unblocking tool includes a short tube and a long tube, and the tail end connected to the inner tube of the powder spray gun specifically includes:

[0046] S61: The unblocking tool consists of two parts: a short tube and a long tube. The diameter of the short tube is adapted to the inner diameter of the tail of the powder spray gun to facilitate insertion without being too loose or too tight, thus ensuring the stability of the connection.

[0047] S62: The long tube is designed to connect with the end of the short tube to form an extended operating lever, so that the operator can apply force to the gun-blocking part from a safe distance;

[0048] S63: The short tube section of the unblocking tool has a quick connection mechanism, namely a threaded engagement or quick clamping device, so as to quickly and safely connect to the tail of the powder spray gun inner tube in high-temperature environments.

[0049] Furthermore, the step S6, which involves tapping the gun-blocking part until it loosens and then cutting off the gun-blocking part, specifically includes:

[0050] S64: After the unblocking tool is securely connected to the tail of the inner tube of the powder spray gun, use manual or mechanical force to tap the blocked part of the gun along the direction of the long tube to loosen the blockage.

[0051] S65: After loosening by tapping, use cutting equipment, including a hand saw or electric cutter, to cut off the blockage at the connection between the short pipe and the end of the powder spray gun inner tube.

[0052] S66: After cutting off the blockage, visually inspect to confirm that the blockage has been completely removed and ensure that the inner tube of the powder spray gun is unobstructed. After ensuring that the inner tube of the powder spray gun is unobstructed, disassemble the unblocking tool and clean and inspect it for the next use.

[0053] Furthermore, S7 specifically includes:

[0054] S71: Select an air compressor with adjustable output pressure, wherein the output pressure is adjustable from 5 to 15 bar;

[0055] S72: Connect the output line of the air compressor to one end of the inner tube of the powder spray gun through an adapter, and adjust the purging pressure of the air compressor to 8 bar;

[0056] S73: The inner tube of the powder spray gun shall be purged with high pressure in an intermittent manner, and the duration of each purging shall not exceed 30 seconds;

[0057] S74: During the purging process, when a rapid drop in pressure is observed in the inner tube of the powder spray gun, it indicates that the blockage has been removed;

[0058] S75: After purging, visually inspect the inner tube of the powder spray gun or use a special tool to check whether its interior is thoroughly cleaned and free of residual blockages.

[0059] The beneficial effects of this invention are:

[0060] This invention combines IoT technology and machine learning algorithms to monitor and predict the clogging status of powder spraying guns in real time. Through this prediction mechanism, the spraying parameters can be automatically adjusted or the operator can be prompted to replace the powder spraying gun before clogging occurs, thereby avoiding production interruptions and equipment damage caused by powder spraying gun clogging, and significantly improving production continuity and equipment utilization efficiency.

[0061] This invention employs a rapid cooling technology that can quickly reduce the temperature of the powder spraying gun to a safe operating level when it becomes clogged. This not only ensures the safety of the operator but also prevents structural damage to the powder spraying gun caused by excessive heat, effectively extending the service life of the powder spraying gun.

[0062] This invention utilizes short and long pipe tools specifically designed for clogging, along with high-pressure purging equipment. These tools and equipment make the handling of clogging powder spraying guns safer and faster, significantly reducing equipment maintenance time and improving production efficiency. Furthermore, these methods reduce physical damage to the powder spraying guns, further extending their service life, lowering maintenance and replacement costs, and solving the problem of powder spraying gun clogging. This can increase the lifespan of the powder spraying gun by more than 10 cycles, resulting in considerable benefits. Attached Figure Description

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

[0064] Figure 1 This is a schematic diagram of a method for dealing with powder spray gun clogging according to an embodiment of the present invention. Detailed Implementation

[0065] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0066] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0067] like Figure 1 As shown, a method for dealing with powder spray gun clogging includes the following steps:

[0068] S1: Prepare an inner tube for the powder spraying gun with a sleeve-like form, so that the inner tube can move along the length of the powder spraying gun under the action of external force;

[0069] S2: A pressure and flow rate sensor is installed in the inner tube of the powder spraying gun to monitor the pressure changes and material flow rate in the inner tube in real time, providing data support for the early warning of blockage of the powder spraying gun.

[0070] S3: The IoT-based control system receives sensor data in real time and analyzes the data through machine learning algorithms to predict whether the powder spraying gun is clogged.

[0071] S4: When the control system predicts that a nozzle blockage is about to occur, it automatically initiates the nozzle blockage prevention program, including adjusting the spraying parameters or sending a signal to replace the powder spraying nozzle.

[0072] S5: For clogged powder spraying guns, use rapid cooling technology to reduce the temperature of the powder spraying gun to a safe operating level;

[0073] S6: Connect the unblocking tool to the tail of the inner tube of the powder spray gun, and tap the blocked part until it is loosened, then cut off the blocked part.

[0074] S7: Use an air compressor to purge the inner tube of the powder spraying gun under high pressure to restore the flowability of the powder spraying gun.

[0075] The inner tube has at least one set of guide structures along the length of the powder spraying gun on its outer surface to enable the inner tube to move linearly relative to the outer tube under the action of external force. The inner surface of the outer tube is provided with guide rails that cooperate with the guide structures to stabilize the movement of the inner tube and reduce damage to the inner tube caused by lateral forces during the gun blockage treatment. The movement range of the inner tube is set with a limit structure to prevent the inner tube from detaching from the outer tube when the powder spraying gun is severely blocked. The limit structure provides a predetermined movement space for the inner tube, ensuring that the blockage can be dealt with in a timely manner without affecting the structural integrity of the powder spraying gun.

[0076] The provided sleeve design improves the feasibility of handling blockages by allowing the inner tube to move along the length of the powder spraying gun under external force, reduces damage to the powder spraying gun, thereby lowering maintenance costs and increasing the service life of the equipment.

[0077] S2 specifically includes:

[0078] S21: Install a flow rate sensor at the inlet of the inner tube of the powder spraying gun. The flow rate sensor is used to monitor the flow rate of the material in real time. The flow rate sensor is connected to the inner tube by thread fastening or welding to ensure that the sensor can work stably and accurately measure the material flow rate in a high-temperature environment.

[0079] S22: Install a pressure sensor at the junction of the inner and outer tubes of the powder spraying gun. The pressure sensor is used to monitor the pressure changes in the inner tube in real time. The installation of the pressure sensor should ensure that it responds quickly to the pressure changes in the inner tube and that the data transmission is not affected by the high temperature environment.

[0080] S23: Both the flow rate sensor and the pressure sensor are connected to a microprocessor, which performs preliminary processing on the sensor data and sends the processed data to the Internet of Things-based control system via wireless or wired means.

[0081] The installed pressure and flow rate sensors can monitor the working status of the powder spraying gun in real time, providing accurate data support for blockage early warning, timely detection of potential blockage risks, and thus taking preventive measures in advance to ensure the continuity and safety of production.

[0082] S3 specifically includes:

[0083] S31: The control system includes an Internet of Things (IoT) interface for receiving data from the flow rate sensor and pressure sensor in the inner tube of the powder spray gun in real time. The IoT interface uses the industry-standard communication protocol MQTT or OPC UA to ensure the stability and real-time performance of data transmission.

[0084] S32: The machine learning algorithm is a supervised learning algorithm, specifically using a support vector machine (SVM) to analyze sensor data. In the algorithm, the flow velocity data is set as v(t) and the pressure data is set as p(t), where t represents the time point.

[0085] S33: The data processing unit in the control system first preprocesses the received data, including normalization and noise reduction, so that the data can be adapted to the algorithm processing.

[0086] S34: The preprocessed data is input into the SVM model, which has been trained using historical data to obtain the optimal classification hyperplane. The specific calculation formula is as follows:

[0087] f(x) = wx + b,

[0088] Where w is the normal vector of the hyperplane, x is the input data vector, and b is the bias term used to predict whether the current operating state tends to block the gun.

[0089] S35: The SVM model uses kernel technology to map the input data to a high-dimensional space, where it finds the hyperplane that maximizes the class margin, thereby improving the accuracy of prediction.

[0090] S36: When the SVM model predicts a risk of clogging in the powder spraying gun, the control system automatically triggers a clogging warning. This warning includes the clogging probability and suggested response measures. The formula for calculating the clogging probability is:

[0091] P block =σ(f(x)),

[0092] Where σ is the sigmoid function, used to convert the model output into a blocking probability;

[0093] The effect of using IoT and machine learning algorithms to analyze sensor data is that it enables early warning through a high-precision blockage prediction model, which significantly reduces downtime caused by nozzle blockage and improves production efficiency and the utilization efficiency of powder spraying nozzles.

[0094] S4 specifically includes:

[0095] S41: The control system is equipped with an early warning trigger module, which is responsible for receiving the jamming prediction result from step S37 and activating the jamming prevention program when the jamming risk is predicted.

[0096] S42: The early warning trigger module is connected to the operation control unit of the powder spraying gun. The control unit includes a spraying parameter setting function, which can adjust parameters such as spraying pressure, spraying rate and spraying angle of the powder spraying gun.

[0097] S43: When the early warning trigger module receives the gun blockage prediction signal, it first tries to prevent gun blockage by adjusting the injection parameters, including reducing the injection rate, increasing the injection angle, or adjusting the injection pressure, in order to reduce the deposition of material in the powder injection gun.

[0098] S44: The control system evaluates the effect of adjusting the spraying parameters. If the adjusted parameters fail to reduce the probability of gun blockage or the risk of gun blockage still exists, the warning trigger module sends a signal to replace the powder spraying gun.

[0099] S45: The powder spraying gun replacement signal includes visual and audible alarms to ensure that the operator can receive the instruction to replace the powder spraying gun in a timely manner. At the same time, the control system records the usage time and spraying parameters of the powder spraying gun for subsequent maintenance and analysis.

[0100] S46: The control system simultaneously sends a detailed gun blockage warning report to maintenance personnel. The report includes predicted blockage data, current spraying parameters, and recommended replacement time, so that maintenance personnel can prepare and arrange the replacement of the powder spraying gun.

[0101] S47: If the powder spraying gun is not replaced within a certain period of time after the powder spraying gun replacement signal is issued, the control system will activate a level 2 warning and raise the alarm level to ensure that the replacement of the powder spraying gun is not delayed, thereby avoiding production interruption or equipment damage.

[0102] By adjusting the spraying parameters or replacing the powder spraying gun in a timely manner, gun clogging was effectively prevented, the equipment failure rate was reduced, and unnecessary material waste was minimized.

[0103] S5 specifically includes:

[0104] S51: Determine the current temperature and target safe operating temperature of the powder spraying gun. The target safe operating temperature should be lower than the heat distortion temperature of the powder spraying gun material to avoid damage to the powder spraying gun structure.

[0105] S52: Select rapid cooling technology. This technology uses liquid nitrogen as the cooling medium. The selected cooling medium can quickly absorb heat and reduce the temperature of the powder spray gun to the target safe operating temperature.

[0106] S53: The cooling medium injection system includes nozzle design and cooling medium supply pipeline. The nozzle can evenly cover the outer surface of the powder spray gun with cooling medium, while the pipeline ensures a continuous supply of cooling medium.

[0107] S54: Before implementing the cooling procedure, ensure that the powder spray gun is safely positioned in the designated cooling area and that the surrounding environment meets safety standards to avoid the risk to the operating environment caused by leakage of cooling medium.

[0108] S55: Activate the cooling medium injection system to cool the powder spraying gun, while monitoring the temperature of the powder spraying gun until it drops to the target safe operating temperature;

[0109] S56: During the cooling process, a temperature sensor is used to monitor the surface temperature of the powder spraying gun in real time to ensure that the cooling effect reaches the expected level and to avoid thermal stress damage to the powder spraying gun material due to excessively rapid cooling.

[0110] S57: After cooling is complete, perform a post-cooling inspection on the powder spraying gun to ensure that its temperature is uniform and there is no structural damage before proceeding with the subsequent gun blockage treatment steps.

[0111] The effect of using rapid cooling technology is to quickly reduce the temperature of the powder spraying gun to a safe level, ensuring the safety of operators when dealing with gun blockages, while avoiding additional equipment damage caused by high temperatures.

[0112] The S6 unblocking tool includes a short tube and a long tube, which are connected to the tail of the powder spray gun's inner tube, specifically including:

[0113] S61: The unblocking tool consists of two parts: a short tube and a long tube. The diameter of the short tube is adapted to the inner diameter of the inner tube of the powder spray gun so that it can be inserted without being too loose or too tight, ensuring the stability of the connection.

[0114] S62: The long tube is designed to connect with the end of the short tube to form an extended operating lever, so that the operator can apply force to the gun-blocking part from a safe distance;

[0115] S63: The short tube section of the unblocking tool has a quick connection mechanism, namely a threaded engagement or quick clamping device, so as to quickly and safely connect to the tail of the powder spray gun inner tube in high-temperature environments.

[0116] In S6, tap the gun-blocking part until it loosens, then cut off the gun-blocking part. Specifically, this includes:

[0117] S64: After the unblocking tool is securely connected to the tail of the inner tube of the powder spray gun, use manual or mechanical force (such as a pneumatic hammer or electric impactor) to tap the blocked part of the gun along the direction of the long tube to loosen the blockage.

[0118] S65: After loosening by tapping, use cutting equipment, including a hand saw or electric cutter, to cut off the blockage at the connection between the short tube and the end of the powder spray gun inner tube. This operation should ensure that the cut is precise to avoid further damage to the powder spray gun inner tube.

[0119] S66: After cutting off the blockage, visually inspect to confirm that the blockage has been completely removed and ensure that the inner tube of the powder spray gun is unobstructed. After ensuring that the inner tube of the powder spray gun is unobstructed, disassemble the unblocking tool and clean and inspect it for the next use.

[0120] The advantage of using unblocking tools, including short and long tubes, for gun blockage removal is that it reliably connects and effectively removes blockages, while avoiding safety accidents and equipment damage that may occur during direct manual operation, thus improving the safety and efficiency of the process.

[0121] S7 specifically includes:

[0122] S71: Select an air compressor with adjustable output pressure, with an output pressure adjustment range of 5 to 15 bar (approximately equivalent to 5 to 15 atmospheres) to meet the cleaning needs of powder spray gun inner tubes with varying degrees of blockage.

[0123] S72: Connect the output line of the air compressor to one end of the inner tube of the powder spraying gun through an adapter to ensure good sealing to prevent high-pressure gas leakage. Adjust the purging pressure of the air compressor to 8 bar to avoid excessive pressure at the beginning, which may damage the inner tube of the powder spraying gun.

[0124] S73: The inner tube of the powder spray gun should be purged with high pressure intermittently. Each purging session should not last more than 30 seconds to prevent damage to the inner tube due to temperature rise.

[0125] S74: During the purging process, when the pressure in the inner tube of the powder spray gun drops rapidly, it indicates that the blockage has been removed. At this time, the purging pressure should be reduced appropriately to reduce wear on the inner tube of the powder spray gun.

[0126] S75: After purging, visually inspect the inner tube of the powder spray gun or use a special tool to check whether its interior is thoroughly cleaned and free of residual blockages.

[0127] The effect of high-pressure purging with an air compressor is to completely remove blockages, restore the flow of the powder spraying gun, avoid production delays caused by blockages, and ensure the normal working performance of the powder spraying gun after maintenance.

[0128] This invention is intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A method for treating powder spraying gun clogging, characterized in that, Includes the following steps: S1: Prepare an inner tube for the powder spraying gun with a sleeve-like form, so that the inner tube can move along the length of the powder spraying gun under the action of external force; The inner tube has at least one set of guide structures along the length of the powder spray gun on its outer surface, and the inner surface of the outer tube has a guide rail that cooperates with the guide structures; the movement range of the inner tube is provided with a limiting structure, which provides a predetermined movement space for the movement of the inner tube. S2: A pressure and flow rate sensor is installed in the inner tube of the powder spraying gun to monitor the pressure changes and material flow rate in the inner tube in real time, providing data support for the early warning of blockage of the powder spraying gun. S3: The IoT-based control system receives sensor data in real time and analyzes the data through machine learning algorithms to predict whether the powder spraying gun is clogged. S4: When the control system predicts that a nozzle blockage is about to occur, it automatically initiates the nozzle blockage prevention program, including adjusting the spraying parameters or sending a signal to replace the powder spraying nozzle. S5: For clogged powder spraying guns, use rapid cooling technology to reduce the temperature of the powder spraying gun to a safe operating level; S5 specifically includes: S51: Determine the current temperature and target safe operating temperature of the powder spraying gun. The target safe operating temperature should be lower than the heat distortion temperature of the powder spraying gun material to avoid damage to the powder spraying gun structure. S52: Select rapid cooling technology, which uses liquid nitrogen as the cooling medium; S53: The cooling medium injection system includes nozzle design and cooling medium supply pipeline. The nozzle can evenly cover the outer surface of the powder spray gun with cooling medium, while the pipeline ensures a continuous supply of cooling medium. S54: Before implementing the cooling procedure, ensure that the powder spray gun is safely positioned in the designated cooling area and that the surrounding environment meets safety standards to avoid the risk to the operating environment caused by leakage of cooling medium. S55: Activate the cooling medium injection system to cool the powder spraying gun, while monitoring the temperature of the powder spraying gun until it drops to the target safe operating temperature; S56: During the cooling process, a temperature sensor is used to monitor the surface temperature of the powder spraying gun in real time to ensure that the cooling effect reaches the expected level and to avoid thermal stress damage to the powder spraying gun material due to excessively rapid cooling. S57: After cooling is complete, perform a post-cooling inspection on the powder spray gun to ensure that its temperature is uniform and there is no structural damage. S6: Connect the unblocking tool to the tail of the inner tube of the powder spray gun, and tap the blocked part until it is loosened, then cut off the blocked part. S7: Use an air compressor to purge the inner tube of the powder spraying gun under high pressure to restore the flowability of the powder spraying gun.

2. The method for treating powder spray gun clogging according to claim 1, characterized in that, S2 specifically includes: S21: Install a flow rate sensor at the inlet of the inner tube of the powder spraying gun. The flow rate sensor is used to monitor the flow rate of the material in real time. The flow rate sensor is connected to the inner tube by thread fastening or welding to ensure that the sensor can work stably and accurately measure the material flow rate in a high-temperature environment. S22: Install a pressure sensor at the junction of the inner and outer tubes of the powder spraying gun. The pressure sensor is used to monitor the pressure changes in the inner tube in real time. The installation of the pressure sensor should ensure that it responds quickly to the pressure changes in the inner tube and that the data transmission is not affected by the high temperature environment. S23: Both the flow rate sensor and the pressure sensor are connected to a microprocessor, which performs preliminary processing on the sensor data and sends the processed data to the Internet of Things-based control system via wireless or wired means.

3. The method for treating powder spray gun clogging according to claim 2, characterized in that, S3 specifically includes: S31: The control system includes an Internet of Things (IoT) interface for receiving data from the flow rate sensor and pressure sensor in the inner tube of the powder spraying gun in real time. The IoT interface uses an industry-standard communication protocol, MQTT or OPC UA. S32: The machine learning algorithm is a supervised learning algorithm, specifically using a Support Vector Machine (SVM) to analyze sensor data. In the algorithm, the flow velocity data is set as... And pressure data set ,in Represents a point in time; S33: The data processing unit in the control system first preprocesses the received data, including normalization and noise reduction, so that the data can be adapted to the algorithm processing. S34: The preprocessed data is input into the SVM model, which has been trained using historical data to obtain the optimal classification hyperplane. The specific calculation formula is as follows: ， in, It is the normal vector of the hyperplane. It is the input data vector. The bias term is used to predict whether the current operating state is likely to result in a jam. S35: The SVM model uses kernel technology to map the input data to a high-dimensional space, where it finds the hyperplane that maximizes the class margin, thereby improving the accuracy of prediction. S36: When the SVM model predicts a risk of clogging in the powder spraying gun, the control system automatically triggers a clogging warning. This warning includes the clogging probability and suggested response measures. The formula for calculating the clogging probability is: ， in It is the sigmoid function, used to convert the model output into a blocking probability.

4. The method for treating powder spray gun clogging according to claim 3, characterized in that, S4 specifically includes: S41: The control system is equipped with an early warning trigger module, which is responsible for receiving the jamming prediction result from step S37 and activating the jamming prevention program when the jamming risk is predicted. S42: The early warning trigger module is connected to the operation control unit of the powder spraying gun. The control unit includes a spraying parameter setting function, which can adjust parameters such as spraying pressure, spraying rate and spraying angle of the powder spraying gun. S43: When the early warning trigger module receives the gun blockage prediction signal, it first tries to prevent gun blockage by adjusting the injection parameters, including reducing the injection rate, increasing the injection angle, or adjusting the injection pressure, in order to reduce the deposition of material in the powder injection gun. S44: The control system evaluates the effect of adjusting the spraying parameters. If the adjusted parameters fail to reduce the probability of gun blockage or the risk of gun blockage still exists, the warning trigger module sends a signal to replace the powder spraying gun. S45: The powder spraying gun replacement signal includes visual and audible alarms to ensure that the operator can receive the instruction to replace the powder spraying gun in a timely manner. At the same time, the control system records the usage time and spraying parameters of the powder spraying gun for subsequent maintenance and analysis. S46: The control system simultaneously sends a detailed gun blockage warning report to maintenance personnel. The report includes predicted blockage data, current spraying parameters, and recommended replacement time, so that maintenance personnel can prepare and arrange the replacement of the powder spraying gun. S47: If the powder spraying gun is not replaced within a certain period of time after the powder spraying gun replacement signal is issued, the control system will activate a level two warning and raise the alarm level to ensure that the replacement of the powder spraying gun is not delayed, thereby avoiding production interruption or equipment damage.

5. The method for treating powder spray gun clogging according to claim 4, characterized in that, The unblocking tool in S6 includes a short tube and a long tube, and the tail end connected to the inner tube of the powder spray gun specifically includes: S61: The unblocking tool consists of two parts: a short tube and a long tube. The diameter of the short tube is adapted to the inner diameter of the tail of the powder spray gun to facilitate insertion without being too loose or too tight, thus ensuring the stability of the connection. S62: The long tube is designed to connect with the end of the short tube to form an extended operating rod; S63: The short tube section of the unblocking tool has a quick connection mechanism, namely a threaded engagement or quick clamping device, so as to quickly and safely connect to the tail of the powder spray gun inner tube in high-temperature environments.

6. The method for treating powder spray gun clogging according to claim 5, characterized in that, The step S6, which involves tapping the gun-blocking part until it loosens and then cutting off the gun-blocking part, specifically includes: S64: After the unblocking tool is securely connected to the tail of the inner tube of the powder spray gun, use manual or mechanical force to tap the blocked part of the gun along the direction of the long tube to loosen the blockage. S65: After loosening by tapping, use cutting equipment, including a hand saw or electric cutter, to cut off the blockage at the connection between the short pipe and the end of the powder spray gun inner tube. S66: After cutting off the blockage, visually inspect to confirm that the blockage has been completely removed and ensure that the inner tube of the powder spray gun is unobstructed. After ensuring that the inner tube of the powder spray gun is unobstructed, disassemble the unblocking tool and clean and inspect it for the next use.

7. A method for treating powder spraying gun clogging according to claim 6, characterized in that, Specifically, S7 includes: S71: Select an air compressor with adjustable output pressure, wherein the output pressure is adjustable from 5 to 15 bar; S72: Connect the output line of the air compressor to one end of the inner tube of the powder spray gun through an adapter, and adjust the purging pressure of the air compressor to 8 bar; S73: The inner tube of the powder spray gun is purged with high pressure in an intermittent manner, and the duration of each purging session does not exceed 30 seconds; S74: During the purging process, when a rapid drop in pressure is observed in the inner tube of the powder spray gun, it indicates that the blockage has been removed; S75: After purging, visually inspect the inner tube of the powder spray gun or use a special tool to check whether its interior is thoroughly cleaned and free of residual blockages.

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