Intelligent control method for glaze spraying water jet cutter machine and application of intelligent control method

Abstract

The invention discloses an intelligent control method and application of a glaze spraying water jet cutter machine. The intelligent control method comprises the following steps that S1, a fluid flow value in the water jet cutter glaze spraying machine is collected in real time, and the collected fluid flow value is transmitted to a system; s2, analyzing the obtained fluid flow value by the system, and dynamically adjusting the fluid flow according to a preset pressure requirement; s3, the system monitors a fluid pressure value through a pressure sensor, and comprehensively analyzes the obtained fluid flow value and the fluid pressure value; according to the method, the fluid flow value and the fluid pressure value of the water jet glaze spraying machine are comprehensively analyzed and monitored, the working state of the main pump is automatically adjusted, a corresponding alarm mechanism is established, the self-diagnosis and recovery functions are achieved, and a water jet nozzle and a pipeline are regularly cleaned in a condition triggering mode.

Description

Technical Field

[0001] The present invention relates to the technical field of automated spraying, and in particular to an intelligent control method for a glaze spraying water jet machine and an application thereof. Background Art

[0002] The glaze spraying water jet machine can be used to evenly spray glaze on the surface of ceramics or glass to increase the aesthetics, wear resistance and waterproofness of the product. It is usually composed of a high-pressure pump, a nozzle system, a glaze supply system, a control system and other parts. The high-pressure pump generates a high-pressure liquid flow, which is transported to the nozzle system through the glaze supply system to atomize the glaze and spray it onto the workpiece surface at high speed. The control system is responsible for accurately controlling various parameters of the equipment to achieve the best glaze spraying effect.

[0003] However, the flow control of traditional glaze-spraying water jet machines is often not precise enough, making it difficult to ensure the stability and uniformity of water jet spraying. Due to the lack of effective flow monitoring and control methods, fluctuations in fluid flow may lead to inconsistent glaze spray thickness, affecting product appearance and performance. When abnormal pressure or fluid flow fluctuations occur in the system, traditional glaze-spraying water jet machines often cannot issue alarms and perform self-diagnosis in a timely manner. Troubleshooting relies on manual experience, which is inefficient and prone to misjudgment. Summary of the invention

[0004] The purpose of the present invention is to provide an intelligent control method for a glaze spraying water jet machine and its application to solve the problems mentioned in the above process.

[0005] To achieve the above object, the present invention provides the following technical solution: an intelligent control method for a glaze spraying water jet machine, comprising the following steps: S1. Collect the fluid flow value in the water jet glaze spraying machine in real time through the flow meter and transmit the collected fluid flow value to the system; S2. The system analyzes the acquired fluid flow value and dynamically adjusts the fluid flow according to the preset pressure requirements; S3. The system monitors the fluid pressure value in real time through the integrated pressure sensor, conducts a comprehensive analysis of the acquired fluid flow value and fluid pressure value, and then automatically adjusts the working state of the main pump; S4. The system regularly cleans the water jet nozzle and pipeline by conditional triggering, and automatically increases or decreases the flow and pressure of the fluid by monitoring; S5. The system compares the current pressure and fluid flow with the set relevant thresholds, generates a corresponding alarm mechanism based on the comparison results, and starts the self-diagnosis function to analyze the cause of the fault, provide maintenance suggestions or automatically adjust parameters to restore normal status.

[0006] Preferably, the flow meter is connected to the system via wireless communication, and sends the collected fluid flow value to the system based on a certain frequency.

[0007] Preferably, the system dynamically adjusts the fluid flow rate in the following steps: The system receives the real-time fluid flow value from the flow meter and sets the current fluid flow value to ; The relationship between pressure and flow rate is expressed in the formula , calculate the ideal fluid flow value under the preset pressure requirement, where P is the preset pressure value, k and n are constant parameters, and Q is the ideal flow value under the preset pressure requirement; Calculate the difference between the current fluid flow value and the ideal fluid flow value, and obtain the formula: , where Indicates the deviation value of the fluid flow, that is, the amount by which the fluid flow needs to be adjusted. is positive, indicating that the fluid flow rate needs to be increased; if If it is negative, it means that the fluid flow rate needs to be reduced; The system sends corresponding instructions for fluid flow regulation to the main pump by signal transmission: increasing the pump speed to increase the fluid flow or reducing the pump speed to reduce the fluid flow.

[0008] Preferably, the system adjusts the main pump according to the fluid flow value and the fluid pressure value in the following steps: The system receives the real-time fluid pressure value from the integrated pressure sensor and sets the current fluid pressure value to ; Calculate the difference between the current fluid pressure and the ideal fluid pressure, and obtain the formula: , where is the deviation value of fluid pressure; The system combines the deviation value of fluid pressure Deviation value of fluid flow After analysis, if the flow rate is low and the pressure is high, the system controls the driving motor of the main pump to reduce the speed of the main pump; if the flow rate is high and the pressure is low, the system controls the driving motor of the main pump to increase the speed of the main pump.

[0009] Preferably, the system counts the number of glaze spraying times by setting a counter to monitor the trigger conditions. When the number of glaze spraying times reaches the preset value of the counter, the system sends an automatic flushing signal. After the system sends the flushing signal, it monitors the changes in flow and pressure in real time, automatically adjusts the working status of the main pump, and increases or decreases the flow and pressure of the fluid.

[0010] Preferably, the steps of the system generating early warning and self-diagnosis recovery through monitoring and analysis are: The system determines the fluid flow threshold within the normal working range through the current glazing task. and fluid pressure threshold ; The system is based on the real-time fluid flow value and fluid pressure value and the current fluid flow threshold and fluid pressure threshold For analysis and comparison: If the fluid flow value Not at fluid flow threshold Range or fluid pressure value Not at fluid pressure threshold When it is within the range, the system immediately sends an alarm signal through voice broadcast and starts the self-diagnosis function; The system collects the changing trends of fluid pressure and fluid flow, equipment operating time, temperature and other parameters that may affect system performance, and compares them with the pre-stored fault mode database. Based on the comparison results of data analysis and fault mode identification, the system determines the specific cause of the fault and provides corresponding maintenance suggestions or automatically adjusts parameters to restore normal status based on the fault type.

[0011] Preferably, a method as described above is used for intelligent control of a glaze spraying water jet machine.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. By installing a flow meter in the glaze supply system to monitor the fluid flow data in real time, the intelligent control system dynamically adjusts the fluid flow according to the preset pressure requirements to ensure the stability and uniformity of the water jet spray, making the glaze spray thickness more consistent, greatly improving the product's appearance quality and performance stability. By integrating a pressure sensor and automatically adjusting the main pump working state in combination with the flow meter data, the water jet spray pressure is optimized, and the pressure parameters can be flexibly adjusted according to different glaze spray requirements, thereby improving energy efficiency; 2. The automatic flushing function can be designed to regularly clean the water jet nozzle and pipeline, effectively avoiding glaze deposition and impurity blockage. The flow rate and pressure of the fluid are automatically increased during the flushing process to ensure thorough cleaning and reduce equipment maintenance costs. The system detects abnormal pressure or fluid flow fluctuations through alarm devices and self-diagnosis functions, quickly analyzes possible causes of failures, and provides maintenance suggestions or automatically adjusts parameters to restore normal conditions, which improves the efficiency of troubleshooting, reduces production interruption time, and improves the reliability and stability of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 The present invention is a method flow chart of an intelligent control method for a glaze spraying water jet machine. DETAILED DESCRIPTION

[0014] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0015] Embodiment 1 A glaze spraying water jet machine intelligent control method of this embodiment, such as Figure 1 As shown, the following steps are included: S1. Collect the fluid flow value in the water jet glaze spraying machine in real time through the flow meter and transmit the collected fluid flow value to the system; S2. The system analyzes the acquired fluid flow value and dynamically adjusts the fluid flow according to the preset pressure requirements; S3. The system monitors the fluid pressure value in real time through the integrated pressure sensor, conducts a comprehensive analysis of the acquired fluid flow value and fluid pressure value, and then automatically adjusts the working state of the main pump; S4. The system regularly cleans the water jet nozzle and pipeline by conditional triggering, and automatically increases or decreases the flow and pressure of the fluid by monitoring; S5. The system compares the current pressure and fluid flow with the set relevant thresholds, generates a corresponding alarm mechanism based on the comparison results, and starts the self-diagnosis function to analyze the cause of the fault, provide maintenance suggestions or automatically adjust parameters to restore normal status.

[0016] Embodiment 2 Based on the first embodiment, this embodiment refers to Figure 1 The intelligent control method of a glaze spraying water jet machine in the first embodiment is further described in detail: The flow meter is connected to the system via wireless communication and sends the collected fluid flow value to the system based on a certain frequency.

[0017] The system dynamically adjusts the fluid flow rate in the following steps: The system receives the real-time fluid flow value from the flow meter and sets the current fluid flow value to ; The relationship between pressure and flow rate is expressed in the formula , calculate the ideal fluid flow value under the preset pressure requirement, where P is the preset pressure value, k and n are constant parameters, and Q is the ideal flow value under the preset pressure requirement; Calculate the difference between the current fluid flow value and the ideal fluid flow value, and obtain the formula: , where Indicates the deviation value of the fluid flow, that is, the amount by which the fluid flow needs to be adjusted. is positive, indicating that the fluid flow rate needs to be increased; if If it is negative, it means that the fluid flow rate needs to be reduced; The system sends corresponding instructions for fluid flow regulation to the main pump by signal transmission: increasing the pump speed to increase the fluid flow or reducing the pump speed to reduce the fluid flow.

[0018] The system adjusts the main pump according to the fluid flow value and fluid pressure value as follows: The system receives the real-time fluid pressure value from the integrated pressure sensor and sets the current fluid pressure value to ; Calculate the difference between the current fluid pressure and the ideal fluid pressure, and obtain the formula: , where is the deviation value of fluid pressure; The system combines the deviation value of fluid pressure Deviation value of fluid flow After analysis, if the flow rate is low and the pressure is high, the system controls the driving motor of the main pump to reduce the speed of the main pump; if the flow rate is high and the pressure is low, the system controls the driving motor of the main pump to increase the speed of the main pump.

[0019] The system counts the number of glaze spraying times by setting a counter to monitor the trigger conditions. When the number of glaze spraying times reaches the preset value of the counter, the system sends out an automatic flushing signal. After the system sends out the flushing signal, it monitors the changes in flow and pressure in real time, automatically adjusts the working status of the main pump, and increases or decreases the flow and pressure of the fluid.

[0020] The counter is connected to the control system through a serial port. The counter adopts an incremental counting method, that is, after each glaze spraying is completed, the counter value increases by one. When the counter reaches the preset value, the system determines that the trigger condition is met and sends an automatic flushing signal. The system generates early warnings and self-diagnosis recovery steps through monitoring and analysis: The system determines the fluid flow threshold within the normal working range through the current glazing task. and fluid pressure threshold ; Among them, different glazing tasks have different requirements for fluid flow and pressure. For fine glazing tasks, lower flow and pressure are required to achieve delicate coating effects. Large-area rapid glazing tasks may require higher flow and pressure to improve work efficiency. The system sets an initial fluid flow threshold range and fluid pressure threshold range for the current glazing task.

[0021] The system is based on the real-time fluid flow value and fluid pressure value and the current fluid flow threshold and fluid pressure threshold For analysis and comparison: If the fluid flow value Not at fluid flow threshold Range or fluid pressure value Not at fluid pressure threshold When it is within the range, the system immediately sends an alarm signal through voice broadcast and starts the self-diagnosis function; Among them, different alarm levels are set according to the deviation of the fluid flow and pressure from the relevant thresholds. When the fluid flow value or the fluid pressure value just exceeds the threshold range by a small part, it is set to a low-level alarm, the voice broadcast tone is relatively mild, and the display screen is prompted in yellow. When the fluid flow value or the fluid pressure value deviates greatly from the threshold range, it is upgraded to a high-level alarm, the voice broadcast is rapid and loud, and the display screen is prompted in red.

[0022] The system collects the changing trends of fluid pressure and fluid flow, equipment operating time, temperature and other parameters that may affect system performance, and compares them with the pre-stored fault mode database. Based on the comparison results of data analysis and fault mode identification, the system determines the specific cause of the fault and provides corresponding maintenance suggestions or automatically adjusts parameters to restore normal status based on the fault type.

[0023] Among them, the failure mode database usually collects data in the following ways: the original manufacturer of the glaze spraying water jet machine will include some known failure conditions and solutions into the database. During the use of the glaze spraying water jet machine, the system will record and store each failure phenomenon, occurrence time, related pressure and data flow and other information in the database.

[0024] Embodiment 3 An application of any of the above methods for intelligent control of a glaze spraying water jet machine.

[0025] In summary, by installing a flow meter in the glaze supply system, real-time monitoring of fluid flow data, and the intelligent control system dynamically adjusting the fluid flow according to the preset pressure requirements, the stability and uniformity of the water jet spraying are ensured, and the glaze spraying thickness is more consistent, which greatly improves the appearance quality and performance stability of the product. By integrating the pressure sensor, the main pump working state is automatically adjusted in combination with the flow meter data to optimize the water jet spraying pressure. The pressure parameters can be flexibly adjusted according to different glaze spraying requirements, which improves energy utilization efficiency. The automatic flushing function can be designed to regularly clean the water jet nozzle and pipeline, effectively avoiding glaze deposition and impurity blockage. The flow and pressure of the fluid are automatically increased during the flushing process to ensure thorough cleaning and reduce equipment maintenance costs. The system detects abnormal pressure or fluid flow fluctuations through alarm devices and self-diagnosis functions, quickly analyzes possible causes of failures, and provides maintenance suggestions or automatically adjusts parameters to restore normal conditions, which improves the efficiency of troubleshooting, reduces production interruption time, and improves the reliability and stability of the equipment.

[0026] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An intelligent control method for a glaze spraying water jet machine, characterized in that: The following steps are involved: S1. Collect the fluid flow value in the water jet glaze spraying machine in real time through the flow meter and transmit the collected fluid flow value to the system; S2. The system analyzes the acquired fluid flow value and dynamically adjusts the fluid flow according to the preset pressure requirements; S3. The system monitors the fluid pressure value in real time through the integrated pressure sensor, conducts a comprehensive analysis of the acquired fluid flow value and fluid pressure value, and then automatically adjusts the working state of the main pump; S4. The system regularly cleans the water jet nozzle and pipeline by conditional triggering, and automatically increases or decreases the flow and pressure of the fluid by monitoring; S5. The system compares the current pressure and fluid flow with the set relevant thresholds, generates a corresponding alarm mechanism based on the comparison results, and starts the self-diagnosis function to analyze the cause of the fault, provide maintenance suggestions or automatically adjust parameters to restore normal status.

2. According to claim 1, a glaze spraying water jet machine intelligent control method is characterized by: The flow meter is connected to the system via wireless communication and sends the collected fluid flow value to the system based on a certain frequency.

3. According to claim 1, a glaze spraying water jet machine intelligent control method is characterized by: The system dynamically adjusts the fluid flow rate in the following steps: The system receives the real-time fluid flow value from the flow meter and sets the current fluid flow value to ; The relationship between pressure and flow rate is expressed in the formula , calculate the ideal fluid flow value under the preset pressure requirement, where P is the preset pressure value, k and n are constant parameters, and Q is the ideal flow value under the preset pressure requirement; Calculate the difference between the current fluid flow value and the ideal fluid flow value, and obtain the formula: , where Indicates the deviation value of the fluid flow, that is, the amount by which the fluid flow needs to be adjusted. is positive, indicating that the fluid flow rate needs to be increased; if If it is negative, it means that the fluid flow rate needs to be reduced; The system sends corresponding instructions for fluid flow regulation to the main pump by signal transmission: increasing the pump speed to increase the fluid flow or reducing the pump speed to reduce the fluid flow.

4. According to claim 1, a glaze spraying water jet machine intelligent control method is characterized by: The system adjusts the main pump according to the fluid flow value and fluid pressure value as follows: The system receives the real-time fluid pressure value from the integrated pressure sensor and sets the current fluid pressure value to ; Calculate the difference between the current fluid pressure and the ideal fluid pressure, and obtain the formula: , where is the deviation value of fluid pressure; The system combines the deviation value of fluid pressure Deviation value of fluid flow After analysis, if the flow rate is low and the pressure is high, the system will reduce the speed of the main pump by controlling the drive motor of the main pump; If the flow rate is too high and the pressure is too low, the system controls the drive motor of the main pump to increase the speed of the main pump.

5. According to claim 1, a glaze spraying water jet machine intelligent control method is characterized by: The system counts the number of glaze spraying times by setting a counter to monitor the trigger conditions. When the number of glaze spraying times reaches the preset value of the counter, the system sends out an automatic flushing signal. After the system sends out the flushing signal, it monitors the changes in flow and pressure in real time, automatically adjusts the working status of the main pump, and increases or decreases the flow and pressure of the fluid.

6. An intelligent control method for a glaze spraying water jet machine and its application according to claim 1, characterized in that: The system generates early warnings and self-diagnosis recovery steps through monitoring and analysis: The system determines the fluid flow threshold within the normal working range through the current glazing task. and fluid pressure threshold ; The system is based on the real-time fluid flow value and fluid pressure value and the current fluid flow threshold and fluid pressure threshold For analysis and comparison: If the fluid flow value Not at fluid flow threshold Range or fluid pressure value Not at fluid pressure threshold When it is within the range, the system immediately sends an alarm signal through voice broadcast and starts the self-diagnosis function; The system collects the changing trends of fluid pressure and fluid flow, equipment operating time, temperature and other parameters that may affect system performance, and compares them with the pre-stored fault mode database. Based on the comparison results of data analysis and fault mode identification, the system determines the specific cause of the fault and provides corresponding maintenance suggestions or automatically adjusts parameters to restore normal status based on the fault type.

7. An application of any of the methods described in 1-6 above for intelligent control of a glaze spraying water jet machine.

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