An insulating high-performance frosted coating rebar manufacturing apparatus and a manufacturing method thereof

Abstract

The application belongs to the technical field of steel bar processing equipment, and relates to an insulating high-performance frosted coating steel bar manufacturing equipment which comprises a feeding mechanism, a shot blasting machine, a first heating machine, a second heating machine, a first spraying house, a second spraying house and a discharging mechanism; is provided with a macro temperature control module and a preset macro temperature control strategy to adjust the output power of the first heating machine; a thermal imaging device is arranged between the first heating machine and the second heating machine, the thermal imaging device comprises a thermal imaging collector and a thermal imaging analysis module, the first heating machine and the second heating machine are separately arranged, the effect of each heating is analyzed through the thermal imaging, the heating strategy of the second heating machine is adjusted through the feedback of the heating of the first heating machine, so that the second powder house can spray the frosted high-performance composite epoxy steel bar coating, the spraying composite effect is ensured, and the problem that the uneven heating of multiple steel bars simultaneously heated due to unstable heat flow affects the spraying quality is avoided.

Description

Technical Field

[0001] This invention relates to the field of steel bar processing equipment technology, specifically to an insulating high-performance frosted coated steel bar manufacturing equipment and its manufacturing method. Background Technology

[0002] Rebar refers to steel used in reinforced concrete and prestressed reinforced concrete, with a circular cross-section, sometimes square with rounded corners. It includes plain round bars, ribbed bars, and twisted bars. In the processing of rebar, the surface needs to be sandblasted and coated, followed by rapid cooling. Existing equipment does not integrate these processing steps, resulting in fragmented and scattered steps. This leads to discontinuity between steps, reducing processing efficiency and hindering the automated and rapid processing of batches of rebar.

[0003] Currently, steel bars require the following processing steps: 1. shot blasting; 2. heating; 3. powder coating; 4. cooling, to achieve surface coating. Invention patent announcement number CN114854287B discloses a preparation process for a frosted high-performance composite epoxy steel bar coating. This frosted high-performance composite epoxy steel bar coating is formed in one step by a spraying process consisting of a base layer and a top layer. The base layer formulation includes: bisphenol A type epoxy A: 25-35%; bisphenol A type epoxy B: 10-20%; modified epoxy material: 20-30%; composite curing agent: 10-12%; leveling agent: 0.8-1.5%; rutile titanium dioxide: 0.5-1.5%; additives: 5-7%; colorant: 0.5-2%; regulator: 2-4%. The remaining portion consists of sheet-like fillers; the topcoat formulation includes: bisphenol A epoxy: 30-40%; modified epoxy material: 35-45%; composite curing agent: 10-20%; additives: 4-6%; modifier: 5-15%; the remaining portion consists of sheet-like fillers. The above-mentioned steel reinforcement coating is formed through a single spraying process. However, a problem was discovered during manufacturing: it requires high uniformity of heating and consistent temperature; otherwise, adhesion and formation will be affected. While this can be controlled through human experience for single or a few steel bars, uneven heating occurs when processing more than 10 steel bars simultaneously, affecting the subsequent spraying quality. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an insulating high-performance frosted coated steel bar manufacturing equipment and method, solving the problems of low automation in steel bar processing and lack of integration in processing steps leading to discontinuous processing steps. To achieve the above objectives, this invention provides the following technical solution: an insulating high-performance frosted coated steel bar manufacturing equipment, comprising a feeding mechanism, a shot blasting machine, a first heating machine, a second heating machine, a first spray booth, a second spray booth, and a unloading mechanism;

[0005] The first heater is equipped with a macro temperature control module, which is configured with a preset macro temperature control strategy to adjust the output power of the first heater;

[0006] A thermal imaging device is configured between the first heating machine and the second heating machine. The thermal imaging device includes a thermal imaging acquisition unit and a thermal imaging analysis module. The thermal imaging acquisition unit is used to acquire thermal imaging images of the target area. The thermal imaging analysis module includes an image segmentation unit, an environmental equalization unit, and a calorific value calculation unit.

[0007] The image segmentation unit is used to segment the thermal imaging image into several thermal imaging regions, each thermal imaging region corresponding to a steel bar and each thermal imaging region having the same shape.

[0008] The environmental equalization unit is used to obtain the environmental calorific value and retrieve the corresponding calorific value conversion function according to the environmental calorific value. The calorific value conversion function is used to convert the calorific value of each pixel in the thermal imaging area to obtain the equalization calorific value of each pixel.

[0009] The calorific value calculation unit is used to calculate the corresponding thermal effect value and heat distribution value based on the equilibrium calorific value of each thermal imaging area;

[0010] The second heating machine has different heating zones for different steel bars. The second heating machine is equipped with an independent temperature control module. The independent temperature control module is configured with a preset independent temperature control strategy to control the temperature of each heating zone according to the heat effect value and heat distribution value.

[0011] Furthermore, it also includes an ambient temperature sensor for detecting ambient temperature. The ambient calorific value is generated corresponding to the ambient temperature. The macroscopic temperature control strategy is configured to acquire the ambient temperature and the target processing temperature, retrieve the corresponding first heating instruction set from a pre-configured heating instruction index table using the ambient temperature and the target processing temperature, and control the output power of the first heating machine using the first heating instruction of the first heating instruction set.

[0012] Furthermore, the first heating instruction set includes a plurality of first heating instructions arranged in sequence, each first heating instruction corresponding to a first trigger condition, and when the corresponding first trigger condition is met, the next first heating instruction in the sequence is triggered.

[0013] Furthermore, the image segmentation unit is configured with a rebar feature library and a rebar shape segmentation library. The rebar feature library stores several rebar feature elements, and the rebar shape segmentation library stores rebar segmentation shapes. Each rebar segmentation shape is indexed by multiple rebar feature elements, and each rebar feature element corresponding to a rebar segmentation shape is configured with an identification segmentation weight. The image segmentation unit is configured with an image segmentation strategy, which includes:

[0014] Step B1: By identifying the features of the steel reinforcement elements in the thermal imaging image, obtain the identification similarity value of each steel reinforcement element feature;

[0015] Step B2: Calculate the cutting index value of each rebar cutting shape using a preset element calculation algorithm, and select the rebar cutting shape with the largest cutting index value as the target cutting shape. Q d To split the index value, h i The identification s-weight of the i-th rebar feature corresponding to the rebar cutting shape is s. i I1 is the identification similarity value corresponding to the i-th rebar feature, and I1 is the total number of rebar feature features corresponding to the rebar cutting shape.

[0016] Step B3: Process the thermal imaging image using a preset contour feature extraction algorithm to obtain several steel bar contours;

[0017] Step B4: Fit the rebar cutting shape to the profile of each rebar to minimize the total fitting cost. Among them, R d Let α1 be the preset item fitting bias weight, and α2 be the preset distance fitting bias weight. Then α1 + α2 = 1, dr ji Let I2 be the distance between the i-th segmentation point and the j-th rebar profile in the target segmentation shape, J1 be the total number of segmentation points corresponding to the target segmentation shape, and dp be the total number of rebar profiles. j This represents the difference between the spacing of the j-th rebar profile and the preset basic spacing of the rebar profile;

[0018] Step B5: Use the fitted envelope region as the thermal imaging area.

[0019] Furthermore, each of the calorific value conversion functions is configured with different input calorific value intervals, and each input calorific value interval is configured with different calorific value multipliers. The calorific value conversion function multiplies the calorific value of each pixel by the calorific value multiplier corresponding to the calorific value interval into which the calorific value falls to obtain the equilibrium calorific value.

[0020] Furthermore, each image point in the thermal imaging area is configured with a thermal effect weight according to its image point position, and the sum of the thermal effect weights is 1. The calorific value calculation unit calculates the thermal effect value by weighting the equal calorific value of each image point according to the thermal effect weights.

[0021] The rebar cutting shape corresponding to the calorific value calculation unit divides the thermal imaging area into several thermal imaging blocks, determines the center image point of each thermal imaging block, calculates the distributed thermal distance between each image point in the thermal imaging block and the center image point through thermal effect weighting, and calculates the heat distribution value based on the distributed thermal distance value.

[0022] have Among them, Dq e D is the heat distribution value. xe M represents the distance M from the center image point to the image point with coordinates xe. xe The thermal effect weight of the image point with coordinate xe, f j () is the thermal mapping function corresponding to the j-th thermal imaging block, reflecting the mapping relationship between the coordinates of the image point and the equilibrium calorific value, Δq j Let be the mean of the equilibrium heat value of the j-th thermal imaging block. J1 is the preset block weight value of the j-th thermal imaging block, and J2 is the total number of thermal imaging blocks.

[0023] Furthermore, the independent temperature control strategy is configured with a temperature control information database, which stores a number of temperature control information. Each temperature control information is configured with a temperature control index condition, and each temperature control index condition is configured with a heat effect range and a heat distribution range. When the heat effect value falls into the corresponding heat effect range and the heat distribution value falls into the corresponding heat distribution range, it is considered that the corresponding temperature control index condition is met and the temperature control information is retrieved. The temperature control information includes a number of temperature control commands.

[0024] Furthermore, the discharge port of the first heating machine is equipped with an air curtain device, and the first spray booth is equipped with a paint heating component for heating the first spray paint to a preset constant temperature paint temperature. The constant temperature paint temperature is generated based on the equilibrium calorific value. A transverse pulley is located at the inlet of the first heating machine, and the transverse pulley is used to drive the steel bars inside the first heating machine to rotate.

[0025] Furthermore, it includes at least 20 steel bar processing stations.

[0026] To achieve the second objective of this invention, a method for manufacturing insulated sandblasted steel bars is provided, along with the aforementioned insulated high-performance frosted coated steel bar manufacturing equipment, comprising the following steps:

[0027] Step 1: Place the required number of steel bars in the designated location on the support frame in the material loading area, ensuring the proper placement of the steel bar lighting fixtures;

[0028] Step 2: Control the lifting cylinder inside the loading carrier to raise the lifting support bar through the external control unit, and place the steel bar in the groove at the top of the lifting support bar;

[0029] Step 3: The winch drive mechanism moves the loading carrier through the chain, positioning the loading carrier at the lower end of the conveying roller. Then, the lifting support bar is lowered to allow the steel bar to fall into the groove of the conveying roller.

[0030] Step 4: The steel bars are conveyed into the shot blasting machine by the conveyor rollers for cleaning, and are then output from the other side of the shot blasting machine after cleaning is completed;

[0031] Step 5: The steel bars are sequentially heated in the first heating machine and the second heating machine, and after heating is completed, they are sent out from the other side of the second heating machine;

[0032] Step Six: After heating, the steel bars are continuously conveyed by the conveyor rollers and sequentially enter the first and second spray booths for spraying.

[0033] Step 7: The steel bars that have completed the spraying process are sent out from the other side of the second spraying booth and enter the cooling zone, where they are cooled by spraying through the spray nozzles;

[0034] Step 8: The cooled steel bars are conveyed to the unloading area by the conveyor rollers, and the unloading of the steel bars is completed through the reverse steps of the loading area.

[0035] Compared with the prior art, the present invention provides a manufacturing equipment and method for manufacturing high-performance insulated frosted coated steel bars, which has the following beneficial effects:

[0036] By separating the first and second heating units, analyzing the effect of each heating cycle, and adjusting the heating strategy of the second heating unit based on the feedback from the first heating unit, the second powder booth can be used to spray a frosted high-performance composite epoxy steel bar coating. This ensures the coating effect while avoiding uneven heating caused by unstable heat flow, which affects the coating quality due to the simultaneous heating of multiple steel bars.

[0037] By setting up a loading carrier, conveyor rollers, shot blasting machine, and cooling zone, when processing reinforcing bars, the operator only needs to place the reinforcing bars neatly on the support frame in the loading area. Then, the lifting cylinder inside the loading carrier raises the lifting support bar, and the reinforcing bar is lifted by the slot at the upper end of the lifting support bar. Then, the winch drive mechanism moves the loading carrier under the conveyor roller via a chain. At the same time, the lifting cylinder controls the lowering of the lifting support bar, and then the lifting support bar places the reinforcing bar into the groove on the outer end face of the conveyor roller. After the reinforcing bar is inserted into the groove of the conveyor roller, the motor-driven conveyor roller rotates at a constant speed, moving the reinforcing bar into the shot blasting machine. After being cleaned by the shot blasting machine, the reinforcing bar is sent out from the other end of the shot blasting machine, and then enters the first heating machine and the second heating machine. After being heated... The reinforcing bars then sequentially enter the first and second spray booths for spraying. The spraying equipment is centrally controlled by an external powder gun control cabinet. After spraying, the reinforcing bars are sent out from the other end of the second spray booth and enter the cooling zone. In the cooling zone, cooling water supplied by the main water supply pipe and transverse branch pipes sprays downwards from the spray nozzles, thus cooling the reinforcing bars. After spray cooling, the reinforcing bars are conveyed to the unloading area by conveyor rollers. In the unloading area, the reinforcing bars are completely removed through the reverse steps of the loading area, completing the reinforcing bar processing operation. This process allows the equipment to not only process reinforcing bars in a standardized and complete manner but also ensure the quality of the processing. It improves the degree of automation while fully integrating the reinforcing bar processing steps, greatly increasing the production efficiency of reinforcing bar processing. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the overall process structure of the present invention;

[0039] Figure 2 This is a schematic diagram of the structure from the feeding area to the shot blasting machine of the present invention;

[0040] Figure 3 This is a schematic diagram showing the location from the cooling zone to the unloading zone in this invention;

[0041] Figure 4 This is a schematic diagram showing the position of the heating machine from the spray booth in this invention.

[0042] In the diagram: 1. Feeding area; 2. Motor; 3. Ground rail; 4. Winch drive mechanism; 5. Chain; 6. Feeding carrier; 601. Lifting cylinder; 602. Lifting support bar; 7. Conveying roller; 8. Shot blasting machine; 9. First heating machine; 10. Second heating machine; 11. First spray booth; 12. Second spray booth; 13. Powder gun control cabinet; 14. Cooling area; 1401. Main water supply pipe; 1402. Horizontal branch pipe; 1403. Spray head; 15. Unloading area; 30. Thermal imaging collector; 31. Air curtain equipment. Detailed Implementation

[0043] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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.

[0044] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," 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 this 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 this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0045] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0046] First, the overall principle of the steel bar manufacturing equipment will be described. Please refer to [link / reference]. Figure 1-4 In this embodiment: an insulating high-performance frosted coating steel bar manufacturing equipment includes a feeding area 1, a motor 2, a ground rail 3, a winch drive mechanism 4, and a chain 5. The motor 2 is located on the outside of the feeding area 1 and drives the conveying roller 7. The ground rail 3 is laid on the ground of the feeding area 1 and allows the feeding carrier 6 to move. The winch drive mechanism 4 is located on both sides of the ground rail 3 and drives the chain 5 for transmission. The chain 5 is located inside the winch drive mechanism 4 and drives the feeding carrier 6. A shot blasting machine 8 is located on the side of the feeding area 1 and performs external sandblasting cleaning on the steel bars. A first heating machine 9 is located on the other side of the shot blasting machine 8. The first heating machine 9 and a second heating machine 10 heat the steel bars. The second heating machine 10 is located on the outside of the first heating machine 9. A powder gun control cabinet 13 is located on the other side of the first heating machine 9 and controls the spraying operation.

[0047] A loading carrier 6 is provided at the upper end of the ground rail 3. The loading carrier 6 drives the lifting cylinder 601 to move. A conveying roller 7 is also provided at the upper end of the loading area 1. The conveying roller 7 conveys the steel bars. A first spray booth 11 is provided on the side of the second heater 10. The first spray booth 11 and the second spray booth 12 spray the steel bars externally. A second spray booth 12 is provided on the same side of the first spray booth 11. A cooling zone 14 is provided on the outside of the second spray booth 12. The cooling zone 14 actively cools the steel bars. A unloading zone 15 is provided at the end of the cooling zone 14. The unloading zone 15 automatically removes the steel bars.

[0048] The loading carrier 6 also includes a lifting cylinder 601 and a lifting support bar 602. The lifting cylinder 601 is fixedly connected to the inside of the loading carrier 6, and the lifting support bar 602 is movably connected to the top of the lifting cylinder 601.

[0049] In this embodiment, the conveying roller 7 is laterally connected to both sides of the feeding area 1, and the motor 2 is movably connected to one end of it. Several sets of conveying rollers 7 are provided and are laterally distributed between the feeding area 1 and the unloading area 15. The cooling area 14 also includes a main water supply pipe 1401, a transverse branch pipe 1402, and a spray head 1403. The main water supply pipe 1401 is fixedly installed on the inner wall end face of the cooling area 14. The transverse branch pipe 1402 is laterally distributed between the two main water supply pipes 1401. The spray head 1403 is fixedly connected to the bottom of the transverse branch pipe 1402 and its opening faces vertically downward.

[0050] Specifically, the spray head 1403 supplies water through the main water supply pipe 1401 and the transverse branch pipe 1402, and sprays water at the spray head 1403 position, which can expand the spray range of the steel bars and thus increase the cooling rate of the steel bars.

[0051] In this embodiment, the top of the lifting support bar 602 is provided with twenty sets of inverted triangular grooves, and the outer periphery of the conveying roller 7 is provided with twenty sets of groove structures with the arc surface facing inward; the number of loading carriers 6 can be determined according to the length of the steel bar, and they move laterally reciprocatingly through the chain 5 and the winch drive mechanism 4.

[0052] Specifically, by providing twenty sets of inverted triangular grooves on the top of the lifting support bar 602 and twenty sets of arc-shaped grooves facing inward on the periphery of the conveying roller 7, it can be ensured that twenty workstations can process steel bars simultaneously.

[0053] In this embodiment, the powder gun control cabinet 13 is connected to the first spray booth 11 and the second spray booth 12 through internal wiring, and the position of the powder gun control cabinet 13 is not limited and can be arranged according to the needs of the site environment; a complete wastewater recycling system is set at the bottom of the cooling zone 14, and the structure of the unloading zone 15 is exactly the same as that of the loading zone 1, but the operation steps are reversed.

[0054] Based on the above-mentioned high-performance insulated frosted coated steel bar manufacturing equipment, a manufacturing method for insulated sandblasted steel bars is proposed:

[0055] Step 1: Place the required number of steel bars for each workstation (the maximum number of workstations in this plan is twenty) in the designated position of the support at position 1 of the loading area, and ensure that the steel bar lighting fixtures are properly positioned.

[0056] Step 2: Control the lifting cylinder 601 inside the loading carrier 6 through the external control unit to lift the lifting support bar 602 and place the steel bar in the groove at the top of the lifting support bar 602;

[0057] Step 3: The winch drive mechanism 4 drives the loading carrier 6 to move via the chain 5, so that the loading carrier 6 is at the lower end of the conveying roller 7. Then, the lifting support bar 602 is controlled to descend, so that the steel bar falls into the groove of the conveying roller 7.

[0058] Step 4: The steel bars are conveyed into the shot blasting machine 8 by the conveyor roller 7 for cleaning, and are output from the other side of the shot blasting machine 8 after cleaning is completed;

[0059] Step 5: The steel bars are sequentially heated by the first heating machine 9 and the second heating machine 10, and are then sent out from the other side of the second heating machine 10 after heating is completed;

[0060] Step Six: After heating, the steel bars are continuously conveyed by the conveying roller 7 and sequentially enter the first spray booth 11 and the second spray booth 12 for sequential spraying;

[0061] Step 7: The steel bars that have completed the spraying process are sent out from the other side of the second spraying chamber 12 and enter the cooling zone 14, where they are sprayed and cooled by the spray nozzles 1403.

[0062] Step 8: The cooled steel bars are conveyed by the conveyor roller 7 to the unloading area 15, and the unloading of the steel bars is completed through the reverse steps of the loading area 1.

[0063] A high-performance insulated frosted coated steel bar manufacturing equipment includes a feeding mechanism, a shot blasting machine 8, a first heating machine 9, a second heating machine 10, a first spray booth 11, a second spray booth 12, and a unloading mechanism.

[0064] The first heating unit 9 is equipped with a macroscopic temperature control module, which has a preset macroscopic temperature control strategy to adjust the output power of the first heating unit 9. It also includes an ambient temperature sensor for detecting ambient temperature. The ambient calorific value corresponds to the ambient temperature. The macroscopic temperature control strategy is configured to acquire the ambient temperature and the target processing temperature, retrieve the corresponding first heating instruction set from a pre-configured heating instruction index table using the ambient temperature and the target processing temperature, and control the output power of the first heating unit 9 using the first heating instruction of the first heating instruction set. The first heating instruction set includes a plurality of sequentially arranged first heating instructions, each corresponding to a first trigger condition. When the corresponding first trigger condition is met, the next first heating instruction in the sequence is triggered. Firstly, through macroscopic temperature control, the output power of the corresponding first heater 9 can be adjusted. At the same time, through triggering conditions and heating commands, the temperature inside the furnace is kept as constant as possible. Because the feeding and discharging of steel bars require space, the temperature of the entire furnace is not sealed. Therefore, when the temperature is too high or too low, dynamic control needs to be performed in a timely manner by meeting the first triggering conditions. The command set can respond to the ambient temperature and the heating needs of steel bars, making it highly targeted.

[0065] A thermal imaging device is configured between the first heating machine 9 and the second heating machine 10. The thermal imaging device includes a thermal imaging acquisition unit 30 and a thermal imaging analysis module. The thermal imaging acquisition unit 30 is used to acquire thermal imaging images of the target area. The thermal imaging analysis module includes an image segmentation unit, an environmental equalization unit, and a calorific value calculation unit.

[0066] The image segmentation unit is used to segment the thermal imaging image into several thermal imaging regions, each corresponding to a rebar and having the same shape. The image segmentation unit is configured with a rebar feature library and a rebar shape segmentation library. The rebar feature library stores several rebar feature elements, and the rebar shape segmentation library stores rebar segmentation shapes. Each rebar segmentation shape is indexed by multiple rebar feature elements, and each rebar feature corresponding to a rebar segmentation shape is configured with an identification segmentation weight. The purpose of this segmentation unit is to ensure that the corresponding contours of different types of rebars can be extracted. Firstly, the contours should exclude environmental content as much as possible, retaining the rebar area. Secondly, multiple rebars should have the same segmentation shape. Therefore, the following scheme is set: the image segmentation unit is configured with an image segmentation strategy, which includes:

[0067] Step B1: By identifying the features of the steel reinforcement elements in the thermal imaging image, obtain the identification similarity value of each steel reinforcement element feature;

[0068] Step B2: Calculate the segmentation index value of each rebar segmentation shape using a preset element calculation algorithm, and select the rebar segmentation shape with the largest segmentation index value as the target segmentation shape. Here, is the segmentation index value, is the identification numerator weight of the first rebar element feature corresponding to the rebar segmentation shape, is the identification similarity value corresponding to the first rebar element feature, and is the total number of rebar element features corresponding to the rebar segmentation shape.

[0069] Step B3: Process the thermal imaging image using a preset contour feature extraction algorithm to obtain several steel bar contours;

[0070] Step B4: Fit the rebar segmentation shape to each rebar profile to minimize the total fitting cost. We have: where is the total fitting cost of the current fitting scheme, is the preset item fitting deviation weight, is the preset distance fitting deviation weight, is the distance between the i-th segmentation item and the i-th rebar profile in the target segmentation shape, is the total number of segmentation items corresponding to the target segmentation shape, is the total number of rebar profiles, and represents the difference between the interval distance of the i-th rebar profile and the preset basic interval distance of the rebar profile. Through profile fitting and distance calculation, while ensuring the shape of each thermal imaging area is consistent, the thermal imaging area should accurately reflect the specific situation as much as possible.

[0071] Step B5: Use the fitted envelope region as the thermal imaging area.

[0072] The environmental equilibration unit is used to acquire the environmental calorific value and, based on this value, retrieves the corresponding calorific value conversion function. The calorific value conversion function converts the calorific value of each pixel in the thermal imaging area to obtain the equilibrium calorific value for each pixel. Each calorific value conversion function is configured with different input calorific value intervals, and each interval is configured with different calorific value multipliers. The calorific value conversion function multiplies the calorific value of each pixel by the calorific value multiplier corresponding to the interval into which the calorific value falls to obtain the equilibrium calorific value. Each pixel in the thermal imaging area is configured with a thermal effect weight based on its position, and the sum of these weights is 1. The calorific value calculation unit calculates the thermal effect value by weighting the equilibrium calorific value of each pixel according to these weights. The thermal effect value reflects the initial heating condition of the reinforcing steel, while the heat distribution value reflects the uniformity of the reinforcing steel heating.

[0073] The rebar cutting shape corresponding to the calorific value calculation unit divides the thermal imaging area into several thermal imaging blocks, determines the center image point of each thermal imaging block, calculates the distributed thermal distance between each image point in the thermal imaging block and the center image point through thermal effect weighting, and calculates the heat distribution value based on the distributed thermal distance value.

[0074] Yes, where is the heat distribution value, reflecting the distance between the image point with coordinates and the center image point, is the heat effect weight of the image point with coordinates , is the heat mapping function corresponding to the i-th thermal imaging block, reflecting the mapping relationship between the image point coordinates and the equilibrium heat value, is the mean of the equilibrium heat value of the i-th thermal imaging block, is the preset block weight value of the i-th thermal imaging block, and is the total number of thermal imaging blocks.

[0075] The calorific value calculation unit is used to calculate the corresponding thermal effect value and heat distribution value based on the equilibrium calorific value of each thermal imaging area;

[0076] The second heating machine 10 has different heating zones corresponding to different reinforcing bars. The second heating machine 10 is equipped with an independent temperature control module. This independent temperature control module is configured with a preset independent temperature control strategy to control the temperature of each heating zone based on the heat effect value and heat distribution value. The independent temperature control strategy is configured with a temperature control information database, which stores several temperature control information entries. Each temperature control information entry is configured with a temperature control index condition, and each temperature control index condition is configured with a heat effect range and a heat distribution range. When the heat effect value falls within the corresponding heat effect range and the heat distribution value falls within the corresponding heat distribution range, the corresponding temperature control index condition is met, and the temperature control information is retrieved. The temperature control information includes several temperature control commands. By indexing through heat effect and heat distribution and retrieving the corresponding heating commands, the heating effect can be further improved, and heating consistency can be ensured.

[0077] The first heating machine 9 has an air curtain device 31 at its outlet, and the first spray booth 11 has a paint heating component for heating the first spray paint to a preset constant temperature. This constant temperature is generated based on the equilibrium calorific value. A transverse pulley is located at the inlet of the first heating machine 9, which drives the steel bars inside the machine to rotate. The air curtain device 31 serves two purposes: first, to prevent heat from flowing out; and second, to cool the surface of the steel bars, preventing excessive surface temperature from affecting the thermal imaging recognition effect. It aims to detect the internal heating effect as much as possible. Because the steel bars have textured surfaces and move forward, they rotate when passing the pulley, ensuring optimal performance.

[0078] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A manufacturing equipment for insulating high-performance frosted coated steel bars, characterized in that: It includes a feeding mechanism, a shot blasting machine, a first heating machine, a second heating machine, a first spray booth, a second spray booth, and a discharging mechanism; The first heater is equipped with a macro temperature control module, which is configured with a preset macro temperature control strategy to adjust the output power of the first heater; A thermal imaging device is configured between the first heating machine and the second heating machine. The thermal imaging device includes a thermal imaging acquisition unit and a thermal imaging analysis module. The thermal imaging acquisition unit is used to acquire thermal imaging images of the target area. The thermal imaging analysis module includes an image segmentation unit, an environmental equalization unit, and a calorific value calculation unit. The image segmentation unit is used to segment the thermal imaging image into several thermal imaging regions, each thermal imaging region corresponding to a steel bar and each thermal imaging region having the same shape. The environmental equalization unit is used to obtain the environmental calorific value and retrieve the corresponding calorific value conversion function according to the environmental calorific value. The calorific value conversion function is used to convert the calorific value of each pixel in the thermal imaging area to obtain the equalization calorific value of each pixel. The calorific value calculation unit is used to calculate the corresponding thermal effect value and heat distribution value based on the equilibrium calorific value of each thermal imaging area; The second heating unit has different heating zones corresponding to different reinforcing bars. The second heating unit is equipped with an independent temperature control module, which is configured with a preset independent temperature control strategy to control the temperature of each heating zone based on the heat effect value and heat distribution value. The image segmentation unit is equipped with a reinforcing bar feature library and a reinforcing bar shape segmentation library. The reinforcing bar feature library stores several reinforcing bar feature data, and the reinforcing bar shape segmentation library stores reinforcing bar segmentation shapes. Each reinforcing bar segmentation shape is indexed by multiple reinforcing bar feature data, and each reinforcing bar feature corresponding to a reinforcing bar segmentation shape is configured with an identification segmentation weight. The image segmentation unit is configured with an image segmentation strategy, which includes: Step B1: By identifying the features of the steel reinforcement elements in the thermal imaging image, obtain the identification similarity value of each steel reinforcement element feature; Step B2: Calculate the cutting index value of each rebar cutting shape using a preset element calculation algorithm, and select the rebar cutting shape with the largest cutting index value as the target cutting shape. ,in To split the index value, For the first The identification numerator weight of the rebar feature corresponding to the rebar cutting shape. For the first Identification similarity values ​​corresponding to each steel reinforcement feature. This refers to the total number of steel reinforcement feature elements corresponding to the steel reinforcement cutting shape; Step B3: Process the thermal imaging image using a preset contour feature extraction algorithm to obtain several steel bar contours; Step B4: Fit the rebar cutting shape to the profile of each rebar to minimize the total fitting cost. ,in, This represents the total fitting cost of the current fitting scheme. The pre-defined item fitting deviation weights, For the preset distance fitting bias weights, we have , To segment the shape of the target, the first The segmentation point and the first The distance between the steel rebar outlines, The total number of segmentation points corresponding to the target segmentation shape. This represents the total number of steel reinforcement bars. Indicates the first The difference between the spacing of each rebar profile and the preset basic spacing of the rebar profile; Step B5: Use the fitted envelope region as the thermal imaging area; Each pixel in the thermal imaging area is assigned a thermal effect weight based on its pixel position. The sum of the thermal effect weights is 1. The calorific value calculation unit calculates the thermal effect value by weighting the balanced calorific value of each pixel according to the thermal effect weights. The rebar cutting shape corresponding to the calorific value calculation unit divides the thermal imaging area into several thermal imaging blocks, determines the center image point of each thermal imaging block, calculates the distributed thermal distance between each image point in the thermal imaging block and the center image point through thermal effect weighting, and calculates the heat distribution value based on the distributed thermal distance value. have ,in, This is the heat distribution value. The coordinates of the reflected image point are The distance between the image point and the center image point. Reflecting coordinates The thermal effect weight of the image point, For the first The thermal mapping function corresponding to each thermal imaging block reflects the mapping relationship between the coordinates of the image point and the equilibrium calorific value. For the first The average equilibrium thermal value of each thermal imaging block For the preset first Block weight values ​​for each thermal imaging block. The total number of thermal imaging blocks; each of the heat value conversion functions is configured with different input heat value intervals, and each input heat value interval is configured with different heat value multipliers. The heat value conversion function multiplies the heat value of each pixel by the heat value multiplier corresponding to the heat value interval into which the heat value falls to obtain the equilibrium heat value.

2. The equipment for manufacturing high-performance insulated frosted coated steel bars as described in claim 1, characterized in that: It also includes an ambient temperature sensor for detecting ambient temperature. The ambient calorific value is generated corresponding to the ambient temperature. The macro temperature control strategy is configured to acquire the ambient temperature and the target processing temperature, retrieve the corresponding first heating instruction set from a pre-configured heating instruction index table based on the ambient temperature and the target processing temperature, and control the output power of the first heating machine through the first heating instruction of the first heating instruction set.

3. The equipment for manufacturing high-performance insulated frosted coated steel bars as described in claim 2, characterized in that: The first heating instruction set includes a number of first heating instructions arranged in sequence. Each first heating instruction corresponds to a first trigger condition. When the corresponding first trigger condition is met, the next first heating instruction in the sequence is triggered.

4. The equipment for manufacturing high-performance insulated frosted coated steel bars as described in claim 1, characterized in that: The independent temperature control strategy is configured with a temperature control information database, which stores a number of temperature control information. Each temperature control information is configured with a temperature control index condition, and each temperature control index condition is configured with a heat effect range and a heat distribution range. When the heat effect value falls into the corresponding heat effect range and the heat distribution value falls into the corresponding heat distribution range, it is considered that the corresponding temperature control index condition is met and the temperature control information is retrieved. The temperature control information includes a number of temperature control commands.

5. The equipment for manufacturing high-performance insulated frosted coated steel bars as described in claim 1, characterized in that: The discharge port of the first heating machine is equipped with an air curtain device, and the first spray booth is equipped with a paint heating component for heating the first spray paint to a preset constant temperature paint temperature. The constant temperature paint temperature is generated based on the equilibrium calorific value. A transverse pulley is provided at the inlet of the first heating machine, and the transverse pulley is used to drive the steel bars inside the first heating machine to rotate.

6. The equipment for manufacturing high-performance insulated frosted coated steel bars as described in claim 1, characterized in that: It includes at least 20 steel bar processing stations.

7. A method for manufacturing high-performance insulated frosted coated steel bars, comprising the manufacturing equipment for high-performance insulated frosted coated steel bars as described in any one of claims 1-6, characterized in that, Includes the following steps: Step 1: Place the required number of steel bars in the designated location on the support frame in the loading area, ensuring that the steel bars are spaced equidistantly. Step 2: Control the lifting cylinder inside the loading carrier to raise the lifting support bar through the external control unit, and place the steel bar in the groove at the top of the lifting support bar; Step 3: The winch drive mechanism moves the loading carrier through the chain, positioning the loading carrier at the lower end of the conveying roller. Then, the lifting support bar is lowered to allow the steel bar to fall into the groove of the conveying roller. Step 4: The steel bars are conveyed into the shot blasting machine by the conveyor rollers for cleaning, and are then output from the other side of the shot blasting machine after cleaning is completed; Step 5: The steel bars are sequentially heated in the first heating machine and the second heating machine, and after heating is completed, they are sent out from the other side of the second heating machine; Step Six: After heating, the steel bars are continuously conveyed by the conveyor rollers and sequentially enter the first and second spray booths for spraying. Step 7: The steel bars that have completed the spraying process are sent out from the other side of the second spraying booth and enter the cooling zone, where they are cooled by spraying through the spray nozzles; Step 8: The cooled steel bars are conveyed to the unloading area by the conveyor rollers, and the unloading of the steel bars is completed through the reverse steps of the loading area.

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