Venturi tube abrasion automatic compensation early warning method

Abstract

The invention provides a venturi tube abrasion automatic compensation early warning method, and relates to the technical field of intelligent control, the method comprises the following steps: establishing a finite element model of a venturi tube, and defining attributes of a venturi tube material in the finite element model, the attributes of the venturi tube material comprising an elastic modulus, a Poisson's ratio and a density parameter; according to the finite element model, finite element analysis is carried out to obtain a finite element analysis result, and according to the finite element analysis result, a key area where the Venturi tube is abraded in the working process and a potential failure mode are determined; and according to a finite element analysis result and historical use data, establishing a wear prediction model to predict wear conditions of the Venturi tube under different working conditions. Through finite element analysis, an abrasion prediction model and real-time monitoring, automatic compensation, early warning and replacement of abrasion of the Venturi tube are achieved, and the spraying efficiency and stability are ensured.

Description

Technical Field

[0001] The invention relates to the field of intelligent control technology, in particular to an automatic compensation and early warning method for venturi tube wear. Background Art

[0002] There are a series of problems in the use of current Venturi powder pumps. Specifically, the wear of the Venturi tube will lead to two main problems:

[0003] First, the powder output of the spray gun gradually decreases, which in turn affects the coating thickness and spraying quality of the sprayed parts. In order to maintain a stable powder output, the operator needs to manually adjust the powder injection gas based on experience, which not only increases the difficulty of operation, but also makes it easy to make mistakes or miss adjustments.

[0004] Second, when the Venturi tube is severely worn to the point where it should be replaced, if the operator fails to detect and replace it in time, it will cause false faults such as no powder discharge or no powder delivery, seriously affecting production progress.

[0005] In addition, many production lines currently adopt the method of uniformly replacing the Venturi tube according to the number of working days, but since the usage time of different spray guns in actual work is not equal, this method will lead to waste. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a Venturi tube wear automatic compensation early warning method, which improves the spraying quality and efficiency and reduces the production cost.

[0007] In order to solve the above technical problems, the technical solution of the present invention is as follows:

[0008] In a first aspect, a Venturi tube wear automatic compensation early warning method is provided, the method comprising:

[0009] Establishing a finite element model of the venturi tube, and defining the properties of the venturi tube material in the finite element model, wherein the properties of the venturi tube material include elastic modulus, Poisson's ratio, and density parameter;

[0010] According to the finite element model, finite element analysis is performed to obtain finite element analysis results, and according to the finite element analysis results, the key areas and potential failure modes of the venturi tube that may cause wear during operation are determined;

[0011] Based on the results of finite element analysis and historical usage data, a wear prediction model is established to predict the wear of the Venturi tube under different working conditions;

[0012] According to the wear prediction model and the working status of the Venturi tube, the wear condition of the Venturi tube is calculated in real time, and the wear condition and the predicted remaining life information are dynamically displayed on the user interface;

[0013] When it is detected that the wear of the Venturi tube reaches a preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the Venturi tube is approaching the service life limit, an early warning command is automatically issued.

[0014] Further, according to the finite element model, a finite element analysis is performed to obtain finite element analysis results, and according to the finite element analysis results, the key areas and potential failure modes of wear of the venturi tube during operation are determined, including:

[0015] Mesh the finite element model of the Venturi tube and set boundary conditions and loads, including inlet and outlet pressure, flow conditions, and temperature loads;

[0016] Determine the solver and solve the finite element model of the Venturi tube. During the solving process, calculate the stress distribution and deformation of the finite element model under different working conditions;

[0017] According to the stress distribution and deformation, the key areas where the Venturi tube wears during operation are analyzed and determined. According to the working conditions and material properties of the Venturi tube, the potential failure modes of the Venturi tube are evaluated, including fatigue failure, plastic deformation, and fracture.

[0018] Furthermore, the finite element model of the Venturi tube is meshed, and boundary conditions and loads are set, including the pressure and flow conditions and temperature loads at the inlet and outlet, including:

[0019] Import the finite element model of the Venturi tube into the finite element analysis software and determine the mesh type according to the geometric shape of the Venturi tube;

[0020] According to the mesh type, determine the size and density of the mesh, identify the wear area and stress concentration area, and increase the mesh density in the wear area and stress concentration area;

[0021] The finite element model of the Venturi tube is meshed according to the mesh type and mesh size, and boundary conditions and loads are set, including the pressure and flow conditions at the inlet and outlet, as well as the temperature load.

[0022] Furthermore, based on the results of finite element analysis and historical usage data, a wear prediction model was established to predict the wear of the Venturi tube under different working conditions, including:

[0023] From the finite element analysis results and historical usage data, collect the stress distribution, deformation, wear data of the Venturi tube under different working conditions, as well as the usage time and working condition records;

[0024] Integrate finite element analysis data with historical usage data to obtain a dataset of venturi tube wear information;

[0025] Extract characteristic variables related to the wear of the Venturi tube from the data set of the wear information of the Venturi tube, including working conditions, material properties, and use time;

[0026] Using characteristic variables, a Venturi tube wear prediction model is constructed to predict the wear of the Venturi tube under different working conditions.

[0027] Furthermore, the calculation formula of the Venturi tube wear prediction model is:

[0028]

[0029] Among them, W represents the expected wear amount of the Venturi tube; a, b, c, d, e and f represent coefficients; g represents the bias term; T represents the working time of the Venturi tube; u represents the index of the working time T of the Venturi tube; P represents the pressure during the working process; m represents the index of the pressure P; Q represents the flow rate during the working process; m represents the material property; m0 represents the reference value of the material property; k represents the index of the material property M.

[0030] Furthermore, in the sprayer controller, a cumulative working timer is used to record the working time of the Venturi tube, and the working status of the Venturi tube is monitored in real time based on sensor data, including pressure and flow.

[0031] Furthermore, when it is detected that the wear of the venturi tube reaches a preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the venturi tube is approaching the service life limit, an early warning instruction is automatically issued, including:

[0032] Determine preset thresholds and service life limits for venturi tube wear;

[0033] The working status data, including pressure and flow, can be obtained in real time through the sensor on the Venturi tube;

[0034] According to the working state data and the wear prediction model, the working time count of the cumulative working time counter is updated to calculate the estimated value of the wear amount of the current venturi tube;

[0035] The estimated wear value of the current Venturi tube is compared with the preset wear threshold. If the estimated wear value of the current Venturi tube is ≥ the wear threshold, the powder injection gas volume will be automatically adjusted to compensate for the reduction in powder output due to wear.

[0036] The remaining life of the Venturi tube is predicted using the wear prediction model, the estimated value of the current wear of the Venturi tube and the working time count. If the predicted remaining life is ≤ the preset life limit, an early warning instruction is issued.

[0037] Furthermore, according to the early warning instruction, a new Venturi tube is replaced, and the life prediction and automatic compensation settings are updated through the status of the new Venturi tube to monitor and predict the wear of the new Venturi tube in real time, including:

[0038] According to the warning information, the sprayer is stopped, the worn venturi tube is removed, a new venturi tube is installed, and the reset button on the sprayer controller user interface is clicked, and the control system performs a reset operation, including clearing the accumulated working timer, resetting the wear prediction model and the automatic compensation logic;

[0039] The control system updates the relevant parameters of the life prediction model and the settings of the automatic compensation logic according to the status information of the new Venturi tube, so as to monitor and predict the wear of the new Venturi tube in real time.

[0040] In a second aspect, a Venturi tube wear automatic compensation warning system includes:

[0041] An acquisition module is used to establish a finite element model of the Venturi tube and define the properties of the Venturi tube material in the finite element model, including elastic modulus, Poisson's ratio, and density parameters; perform finite element analysis based on the finite element model to obtain finite element analysis results, and determine the key areas and potential failure modes of wear of the Venturi tube during operation based on the finite element analysis results; establish a wear prediction model based on the results of the finite element analysis and historical usage data to predict the wear of the Venturi tube under different working conditions;

[0042] The processing module is used to calculate the wear of the Venturi tube in real time according to the wear prediction model and the working status of the Venturi tube, and dynamically display the wear status and predict the remaining life information on the user interface; when it is detected that the wear of the Venturi tube reaches a preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the Venturi tube is approaching the service life limit, a warning instruction is automatically issued.

[0043] According to a third aspect, a computing device includes:

[0044] one or more processors;

[0045] The storage device is used to store one or more programs. When the one or more programs are executed by the one or more processors, the one or more processors implement the method described.

[0046] In a fourth aspect, a computer-readable storage medium stores a program, and when the program is executed by a processor, the method described is implemented.

[0047] The above solution of the present invention includes at least the following beneficial effects:

[0048] Finite element analysis and wear prediction models can accurately predict the wear of the Venturi tube, and automatically adjust the powder injection gas volume to compensate for the reduction in powder output before the wear reaches a level that affects the spraying quality. This ensures the stability of the powder output during the spraying process, thereby improving the thickness uniformity and overall quality of the coating. By real-time monitoring and predicting the wear of the Venturi tube, early warning instructions can be issued in a timely manner when the Venturi tube is close to the service life limit. This avoids equipment failure and damage caused by excessive wear of the Venturi tube, thereby extending the overall service life of the equipment. By monitoring and compensating for the wear of the Venturi tube, automated monitoring and compensation are achieved, reducing manual intervention, and reducing errors and improper operations caused by human factors.

[0049] Through real-time monitoring and early warning, the present invention can ensure that the venturi tube works in a normal state, avoiding the degradation of spraying quality and production interruption caused by wear. This improves production efficiency and reduces costs caused by equipment failure, coating quality problems and increased scrap rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 It is a flow chart of a Venturi tube wear automatic compensation early warning method provided by an embodiment of the present invention.

[0051] Figure 2 It is a schematic diagram of a Venturi tube wear automatic compensation warning system provided by an embodiment of the present invention.

[0052] Figure 3 It is a structural diagram of a spray machine controller provided by an embodiment of the present invention.

[0053] Explanation of the reference numerals: 1. Venturi tube; 2. Powder injection nozzle; 3. Powder pump body; 4. Powder pump seat; 5. Powder extraction pipe; 6. Powder delivery pipe for spray gun; 7. Accumulated working timer. DETAILED DESCRIPTION

[0054] The exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0055] like Figure 1 As shown, an embodiment of the present invention provides a Venturi tube wear automatic compensation early warning method, the method comprising the following steps:

[0056] Step 11, establishing a finite element model of the venturi tube, and defining the properties of the venturi tube material in the finite element model, wherein the properties of the venturi tube material include elastic modulus, Poisson's ratio, and density parameter;

[0057] Step 12, performing finite element analysis according to the finite element model to obtain finite element analysis results, and determining the key areas and potential failure modes of wear of the venturi tube during operation according to the finite element analysis results;

[0058] Step 13, based on the results of the finite element analysis and the historical usage data, a wear prediction model is established to predict the wear of the venturi tube under different working conditions;

[0059] Step 14, according to the wear prediction model and the working state of the Venturi tube, the wear condition of the Venturi tube is calculated in real time, and the wear condition and the predicted remaining life information are dynamically displayed on the user interface;

[0060] Step 15, when it is detected that the wear of the venturi tube reaches a preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the venturi tube is approaching the service life limit, a warning instruction is automatically issued.

[0061] In an embodiment of the present invention, by accurately establishing a finite element model of the venturi tube and clearly defining its material properties (such as elastic modulus, Poisson's ratio, density, etc.), accurate basic data is provided for finite element analysis and wear prediction. This helps to more accurately simulate the stress state and wear of the venturi tube during operation. Through finite element analysis, the stress distribution and deformation of the venturi tube during operation can be intuitively observed, thereby accurately determining the key areas of wear and potential failure modes. This helps to specifically enhance the wear resistance of these areas and extend the service life of the venturi tube.

[0062] Combining the results of finite element analysis and historical usage data, the established wear prediction model can accurately predict the wear of the Venturi tube under different working conditions. This provides a scientific basis for formulating reasonable maintenance plans and replacement strategies, which helps to reduce maintenance costs and replacement frequency. By calculating the wear of the Venturi tube in real time and dynamically displaying the wear status and predicted remaining life information on the user interface, operators can intuitively understand the current status and remaining service life of the Venturi tube. This helps to take timely measures for maintenance or replacement to avoid equipment failure and deterioration of spraying quality.

[0063] When it is detected that the wear of the Venturi tube has reached a preset threshold, the powder injection gas volume can be automatically adjusted to compensate for the reduction in powder output, ensuring the stability of the spraying process. At the same time, if it is predicted that the Venturi tube is approaching the service life limit, an early warning instruction can be automatically issued to remind the operator to replace the new Venturi tube in time to avoid equipment failure and spraying quality problems. After replacing the new Venturi tube, the wear of the new Venturi tube can be monitored and predicted in real time by updating the life prediction and automatic compensation settings. This ensures that the new Venturi tube can work in the best condition, extending the overall service life of the equipment and reducing maintenance costs and replacement frequency.

[0064] In a preferred embodiment of the present invention, in the above step 11, a finite element model of the venturi tube is established, and the properties of the venturi tube material are defined in the finite element model. The properties of the venturi tube material include elastic modulus, Poisson's ratio, and density parameters, which may include:

[0065] Collect detailed property information of the materials used for the venturi tube, including but not limited to: elastic modulus, which measures the material's ability to resist deformation when subjected to force. Poisson's ratio, which describes the proportional relationship between lateral strain and longitudinal strain when the material is subjected to force. Density, the ratio of the material's mass to its volume. This information is obtained through data sheets provided by material suppliers, professional literature or experimental tests. Based on the analysis requirements and available resources, determine the finite element analysis software, such as ANSYS. The software provides powerful modeling, analysis and post-processing capabilities. In the finite element software, use the modeling tools to create a three-dimensional geometric model of the venturi tube. It involves drawing the outer contour of the venturi tube and then generating a solid model through operations such as rotation and stretching. Ensure that the size and shape of the model are consistent with the actual venturi tube.

[0066] In the material library of the finite element software, create a new material entry and enter the previously collected property data of the Venturi tube material, including elastic modulus, Poisson's ratio, and density. These data will be used for finite element analysis. Apply the defined material properties to the geometric model of the Venturi tube. This can be done by selecting all or part of the model and then specifying the material properties. Make sure that the material properties are correctly applied to the entire Venturi tube model.

[0067] In a preferred embodiment of the present invention, the above step 12, based on the finite element model, performs finite element analysis to obtain finite element analysis results, and based on the finite element analysis results, determines the key areas and potential failure modes of wear of the venturi tube during operation, which may include:

[0068] Step 112, meshing the finite element model of the venturi tube, and setting boundary conditions and loads, including pressure and flow conditions and temperature loads at the inlet and outlet;

[0069] Step 113, determining a solver, and solving the finite element model of the venturi tube, and in the solving process, calculating the stress distribution and deformation of the finite element model under different working conditions;

[0070] Step 114, analyzing and determining the key areas where the Venturi tube is worn during operation based on the stress distribution and deformation, and evaluating the potential failure modes of the Venturi tube including fatigue failure, plastic deformation, and fracture based on the working conditions and material properties of the Venturi tube.

[0071] In an embodiment of the present invention, the finite element model of the venturi tube is meshed to ensure that the mesh density of key areas (such as the inlet, throat, outlet, etc.) is high enough to capture stress concentration and deformation details. The mesh type (such as tetrahedron, hexahedron, shell element, etc.) and mesh size are selected to balance the calculation accuracy and calculation efficiency. According to the actual working conditions of the venturi tube, the pressure and flow conditions of the inlet and outlet are set. For example, the pressure at the inlet can be specified as a constant value, and the flow at the outlet can be specified as a function or a curve that changes with time. Consider the influence of temperature load on the venturi tube and set it accordingly in the finite element model. According to the analysis type and solution scale, select an iterative solver for solution.

[0072] Convergence criterion: Set the convergence criterion to residual less than 1e-6 to ensure the accuracy of the solution;

[0073] Iterations: Set the number of iterations to 1000 as the maximum number of iterations in the solution process;

[0074] Time step: Set the time step to 0.01s to control the time advancement during the solution process. Start the configured solver and solve the finite element model of the Venturi tube. During the solution process, monitor the convergence of the solver and the change of results in real time. Ensure that the solution process is stable and the results are reasonable. If there are convergence problems or abnormal results, adjust the model or solver parameters in time, such as adjusting the mesh size, number of iterations, time step, etc., to improve the solution effect.

[0075] According to the solution results, the stress distribution and deformation of the Venturi tube during operation are analyzed. Focus on the stress concentration and deformation in key areas such as the inlet, throat and outlet. Find out the areas with large stress concentration and deformation, which are the key areas of the Venturi tube that are susceptible to wear during operation. If the stress in the key areas exceeds the fatigue limit of the material, fatigue failure may occur. It is necessary to pay attention to the stress level and number of cycles in these areas to evaluate the fatigue life. If the deformation is too large and cannot be fully recovered, plastic deformation may occur. It is necessary to pay attention to the deformation amount and material plastic properties in these areas to evaluate the risk of plastic deformation. If the stress exceeds the fracture strength of the material, fracture may occur. It is necessary to pay attention to the stress level and material fracture properties of the entire Venturi tube to evaluate the risk of fracture.

[0076] Taking a certain type of Venturi tube as an example, its working conditions and material properties are known, and finite element analysis is performed.

[0077] For meshing, hexahedral meshes are used with a mesh size of 1mm and encryption in key areas. Boundary conditions and loads are set, with an inlet pressure of 2bar and an outlet flow of 50L / min, and gravity and temperature loads are considered. Select the iterative solver, set the convergence criterion, number of iterations, and time step. Start the solver for solving, monitor the solution process and ensure convergence. According to the solution results, it was found that there were large stress concentrations and deformations at the inlet and throat of the Venturi tube. After evaluating the potential failure modes, it is believed that fatigue failure and plastic deformation may occur in these areas. Appropriate measures need to be taken to improve the wear resistance and service life of the Venturi tube.

[0078] Through finite element analysis, the wear and failure that may occur in the working process of the Venturi tube can be predicted in the design stage, so as to avoid problems in actual application. This helps to reduce the number of design iterations, shorten the product development cycle, and improve design efficiency. According to the results of finite element analysis, the structure of the Venturi tube can be optimized, such as strengthening the material in key areas, changing the shape or size, etc., to improve its wear resistance and service life. This helps to reduce production costs and maintenance costs and improve the economic benefits of the product. Through finite element analysis, the weak links and potential failure modes of the Venturi tube during the working process can be found, so that corresponding preventive measures can be taken. This helps to improve the reliability and safety of the product and reduce the possibility of accidents. The results of finite element analysis can provide a scientific basis for the maintenance and replacement of the Venturi tube. According to the analysis results, a reasonable maintenance plan and replacement strategy can be formulated to ensure that the Venturi tube is always in good working condition.

[0079] In another preferred embodiment of the present invention, the above step 112, meshing the finite element model of the venturi tube, and setting boundary conditions and loads, including pressure and flow conditions and temperature loads at the inlet and outlet, may include:

[0080] Step 1122, importing the finite element model of the venturi tube into the finite element analysis software, and determining the mesh type according to the geometric shape of the venturi tube;

[0081] Step 1123, determining the size and density of the grid according to the grid type, identifying the wear area and the stress concentration area, and increasing the grid density in the wear area and the stress concentration area;

[0082] Step 1124, meshing the finite element model of the Venturi tube according to the mesh type and mesh size, and setting boundary conditions and loads, including pressure and flow conditions and temperature loads at the inlet and outlet.

[0083] In an embodiment of the present invention, the constructed finite element model of the Venturi tube (saved in CAD file format) is imported into the selected finite element analysis software, such as ANSYS, ABAQUS, etc. Based on the geometric shape of the Venturi tube, a suitable mesh type is selected. For example, for a Venturi tube with a complex surface, a tetrahedral mesh may be selected to better adapt to the geometric shape; for an area with a more regular shape, a hexahedral mesh may be selected to improve the calculation efficiency. According to the analysis accuracy requirements, the limitation of computing resources and the specific size of the Venturi tube, the basic size and overall density of the mesh are determined. For example, for critical areas, the mesh size may be set to a smaller value, such as 1mm; while for non-critical areas, the mesh size is set to a larger value, such as 5mm. Through empirical judgment or preliminary analysis, possible wear areas and stress concentration areas in the Venturi tube are identified. For example, in the contraction section and diffusion section of the Venturi tube, due to the change of fluid velocity and the distribution of pressure, these areas are often prone to wear and stress concentration. In these critical areas, the density of the mesh is appropriately increased. For example, the mesh size in the critical area is set to half or smaller than that in the non-critical area to ensure that more details and more accurate stress distribution can be captured in these areas. Use the mesh generation tool in the finite element analysis software to mesh the finite element model of the Venturi tube according to the determined mesh type and size. During the meshing process, attention should be paid to maintaining the continuity and quality of the mesh to avoid distortion, overlap or unqualified units.

[0084] According to the actual working conditions of the Venturi tube, set the corresponding boundary conditions. For example, set the velocity inlet boundary condition at the inlet of the Venturi tube to simulate the inflow of the fluid; set the pressure outlet boundary condition at the outlet to simulate the outflow of the fluid. At the same time, for the wall of the Venturi tube, you can set the no-slip boundary condition to simulate the interaction between the fluid and the wall. Apply pressure loads at the inlet and outlet to simulate the pressure distribution of the Venturi tube during operation. Set flow conditions to simulate the flow state of the fluid when passing through the Venturi tube. These flow conditions can be volume flow, mass flow or velocity flow, etc., depending on the needs of the analysis and actual conditions. If the Venturi tube is affected by temperature during operation, temperature loads must also be applied to the model. These temperature loads can be constant values ​​or functions that vary with space or time. For example, a constant temperature value can be set on the wall of the Venturi tube to simulate the temperature influence of the external environment.

[0085] Assume that a finite element analysis is being performed on a specific venturi tube, which has a convergent-divergent geometry and is used to measure the flow rate of a fluid. During the analysis, the following specific steps are taken:

[0086] The geometric model of the Venturi tube was imported into ANSYS software, and the tetrahedral mesh type was selected for division. According to the analysis accuracy requirements and computing resource limitations, the mesh size was set to 2mm, and the mesh was encrypted for key areas such as the contraction section and the diffusion section. The mesh size after encryption was 1mm. After the mesh division was completed, the boundary conditions were set: the velocity inlet boundary condition was set at the inlet, and the velocity was 10m / s; the pressure outlet boundary condition was set at the outlet, and the pressure was atmospheric pressure. At the same time, a no-slip boundary condition was set for the wall of the Venturi tube. The corresponding pressure loads were applied at the inlet and outlet respectively; the flow condition of the volume flow rate was set to 1L / s; and considering that the Venturi tube may be affected by the external ambient temperature during operation, a constant temperature load of 25°C was applied to the wall.

[0087] Selecting the right mesh type ensures that the mesh matches the geometry of the model, reduces mesh distortion and calculation errors, and thus improves the accuracy and reliability of the analysis. Determining the basic size and overall density of the mesh is a key step in meshing. Appropriate mesh size and density can control the scale and time of calculations while ensuring calculation accuracy. Identify possible wear areas and stress concentration areas in the Venturi tube, and appropriately increase the mesh density in these key areas. Encrypted meshes can better capture the details and stress changes in these areas and improve the accuracy of the analysis. By setting the right mesh size and density and encrypting the mesh in key areas, the accuracy and reliability of the analysis results can be ensured. At the same time, encrypted meshes can also improve the accuracy of identifying stress concentration and wear areas, which is beneficial for the design and optimization of the Venturi tube. Through precise meshing and reasonable boundary conditions and load settings, the stress state and fluid flow of the Venturi tube in actual work can be simulated. This helps to accurately evaluate the performance of the Venturi tube and predict possible wear and stress concentration areas. At the same time, it can also improve the accuracy and reliability of the analysis and reduce calculation errors and uncertainties.

[0088] In a preferred embodiment of the present invention, the above step 13, based on the results of finite element analysis and historical usage data, establishes a wear prediction model to predict the wear of the venturi tube under different working conditions, which may include:

[0089] Step 131, collecting stress distribution, deformation, wear data, usage time, and working condition records of the Venturi tube under different working conditions from the finite element analysis results and historical usage data;

[0090] Step 132, integrating the finite element analysis data and the historical usage data to obtain a data set of venturi tube wear information;

[0091] Step 133, extracting characteristic variables related to the wear of the Venturi tube from the data set of the wear information of the Venturi tube, including working conditions, material properties, and use time;

[0092] Step 134, using the proposed characteristic variables, constructing a venturi tube wear prediction model to predict the wear of the venturi tube under different working conditions.

[0093] In an embodiment of the present invention, finite element analysis data (including stress distribution and deformation data of the venturi tube under different working conditions), data (wear amount recorded in accelerated wear experiment) and historical use data (wear records during actual use) are integrated to form a comprehensive data set containing venturi tube wear information. Characteristic variables related to venturi tube wear are extracted from the comprehensive data set. Characteristic variables include working conditions (inlet pressure, outlet flow, working temperature), material properties (elastic modulus, Poisson's ratio, density), use time, and stress distribution and deformation characteristics (such as maximum stress, average stress, deformation, etc.) obtained from finite element analysis. The characteristic variables are normalized or standardized to improve the training efficiency and prediction accuracy of the model. A neural network algorithm is selected to construct a venturi tube wear prediction model. The extracted characteristic variables are used as input data, and the wear amount is used as output data to construct a neural network model. The performance of the model is evaluated using methods such as cross-validation, such as K-fold cross-validation, where the data set is divided into K parts, and K-1 parts of data are used for training each time, and 1 part of data is used for verification, and repeated K times, and the average value is taken as the performance indicator of the model. Based on the evaluation results, the number of layers and nodes of the neural network are tuned to improve the prediction accuracy of the model. Use an independent test data set to verify the prediction ability of the model. The test data set should contain some Venturi wear data that has not been used in the training process.

[0094] By comparing the model's prediction results with the actual wear data, the mean square error is calculated to evaluate the accuracy and reliability of the model. The formula for calculating the mean square error is: Where MSE represents mean square error; n represents the number of samples in the test data set; y i represents the actual wear amount of the i-th sample; Represents the predicted wear amount of the model for the i-th sample. If the prediction error of the model is within an acceptable range, it means that the model has good generalization ability and can be used for actual Venturi tube wear prediction. The verified wear prediction model is applied to the actual Venturi tube wear prediction. For example, for a Venturi tube with working conditions of inlet pressure 2 bar, outlet flow 50 L / min, and working temperature 25 ° C, the corresponding characteristic variables are input into the model to obtain the predicted results of the wear amount. According to the prediction results, formulate a reasonable maintenance plan and replacement strategy. If the prediction results show that the wear amount is large and close to the limit value, replacement or maintenance operations should be performed in advance. In the actual application process, new wear data is continuously collected to update and optimize the model to improve its prediction accuracy and applicability.

[0095] By integrating finite element analysis and historical usage data, a more comprehensive and accurate wear prediction model for the Venturi tube can be established. This model can consider the impact of multiple factors on wear, thereby improving the accuracy of the prediction. Based on the results of the wear prediction model, a reasonable maintenance plan and replacement strategy can be formulated. This helps to avoid replacing the Venturi tube too early or too late, thereby reducing costs and improving equipment reliability. By predicting the wear of the Venturi tube under different working conditions, corresponding preventive measures can be taken to extend its service life. For example, working conditions can be adjusted, material wear resistance can be enhanced, or regular maintenance can be performed. Accurate wear prediction can help companies detect and solve potential wear problems in a timely manner, thereby avoiding failures or accidents caused by wear. This helps to reduce maintenance costs and downtime and improve the economic benefits of the company.

[0096] In a preferred embodiment of the present invention, the above step 14, based on the wear prediction model and the working state of the venturi tube, calculates the wear condition of the venturi tube in real time, and dynamically displays the wear condition and predicted remaining life information on the user interface, which may include:

[0097] In an embodiment of the present invention, a sensor is installed in the working environment of the venturi tube to collect working condition data (such as inlet pressure, outlet flow, working temperature, etc.) in real time. Ensure smooth communication between the sensor and the data processing system. Preprocess the collected data, such as filtering and denoising, to ensure the accuracy and reliability of the data. Receive real-time data transmitted from the sensor and process it to extract characteristic variables. Normalize or standardize the characteristic variables according to the needs of the wear prediction model. Input the processed characteristic variables into the wear prediction model to calculate the real-time wear amount. Ensure that the wear prediction model has been trained and verified and has a high prediction accuracy. Integrate the wear prediction model in the real-time data processing system so that it can receive the processed characteristic variables and output the wear amount prediction results. Post-process the prediction results, such as converting them into a more intuitive wear degree representation or remaining life estimation. Design a user interface so that it can display the wear condition of the venturi tube and the predicted remaining life information in real time. The user interface should have good interactivity, allowing users to view historical data, adjust display parameters, etc. Develop an interface between the user interface and the real-time data processing system to ensure that data can be accurately and timely transmitted and displayed. Integrate various modules such as data acquisition, real-time data processing, wear prediction model application and user interface to form a complete real-time wear monitoring system. Test the system, including functional testing, performance testing and stability testing, to ensure that the system can operate normally and meet actual needs. Deploy the real-time wear monitoring system to the actual working environment of the venturi tube for actual application. Regularly maintain and update the system to ensure the stability and accuracy of the system.

[0098] Assuming that the construction and verification of the Venturi tube wear prediction model has been completed, and the real-time data processing system and user interface have been developed, now apply this system to the actual Venturi tube wear monitoring and perform the following operations:

[0099] Install sensors on the venturi tube to collect data such as inlet pressure, outlet flow and working temperature in real time. Develop data acquisition and transmission modules to ensure smooth communication between sensors and data processing systems. Perform preprocessing on the collected data, such as filtering and denoising. Receive and process the data transmitted by the sensor in the real-time data processing system, extract characteristic variables and perform normalization. Input the processed characteristic variables into the trained and verified wear prediction model to calculate the real-time wear amount. Estimate the remaining life of the venturi tube based on the prediction results. Design and develop a user interface that can display the wear status of the venturi tube and predict the remaining life information in real time. The user interface should have good interactivity, allowing users to view historical data, adjust display parameters, etc. Integrate the various modules to form a complete real-time wear monitoring system. Test the system to ensure that the system's functions and performance meet actual needs. Deploy the real-time wear monitoring system to the actual working environment of the venturi tube for actual application. Regularly maintain and update the system to ensure the stability and accuracy of the system. At the same time, collect user feedback, continuously optimize system functions and user interface design, and improve user experience.

[0100] In a preferred embodiment of the present invention, the calculation formula of the Venturi tube wear prediction model is:

[0101]

[0102] Among them, W represents the expected wear amount of the Venturi tube; a, b, c, d, e and f represent coefficients; g represents the bias term; T represents the working time of the Venturi tube; u represents the index of the working time T of the Venturi tube; P represents the pressure during the working process; m represents the index of the pressure P; Q represents the flow rate during the working process; M represents the material property; M0 represents the reference value of the material property; k represents the index of the material property M.

[0103] In the embodiment of the present invention, the model parameters a, b, c, d, e and f obtained by fitting historical data are collected to determine the reference value M0 of the material property. The actual working conditions of the venturi tube are obtained: working time T, pressure P, flow rate Q and material property M. The coefficient a, working time T and index u are substituted into the formula to calculate the value of the first term a×T u Substitute the coefficient b, pressure P, flow rate Q and exponent m into the formula to calculate the value of the second term b×P m×log(Q+1). Substitute the coefficient c, material property M, reference value M0, and index k into the formula to calculate the value of the third term. Substituting the coefficients d, e, f and the working time T into the formula, the exponential function exp is calculated, which represents the power of e (the base of the natural logarithm), plus the bias term g, which is a constant term in the model, to obtain Adding the five items together, the estimated wear amount W is obtained.

[0104] Assume that the following model parameters have been obtained through data collection and parameter estimation:

[0105] Model parameters: a=0.01, b=0.02, c=0.03, d=0.04, e=0.05, f=0.1, g=0.2, u=2, m=3, k=1.5.

[0106] Input data: T = 1000 hours, P = 2 bar, Q = 50 L / min, M = 200 (assumed to be a value relative to a reference value), M0 = 100 (assumed to be a reference value of the material property).

[0107] Calculate each term:

[0108] First item: 0.01×1000 2 =1000;

[0109] Second term: 0.02×2 3 ×log(50+1)≈0.02×8×3.912≈0.626 (rounded to three decimal places);

[0110] Item 3: (round to three decimal places);

[0111] Item 4: (Because the exponential term is very small, it can be approximated to 1);

[0112] Bias term: 0.2;

[0113] The sum is the expected wear amount: W = 1000 + 0.626 + 0.085 + 0.04 + 0.2 ≈ 1000.951 (rounded to three decimal places). Therefore, given the data collection and parameter estimation, the expected wear amount of the Venturi tube is about 1000.951.

[0114] In another preferred embodiment of the present invention, in the sprayer controller, the working time of the venturi tube is recorded by using a cumulative working timer, and the working state of the venturi tube is monitored in real time according to the sensor data, including pressure and flow, which may include:

[0115] In an embodiment of the present invention, a programmable logic controller (PLC) is used, which has data processing and logic control capabilities, as the central processing unit of the system. The cumulative working timer is an internal variable of the PLC, which is used to accurately record the working time of the venturi tube, accumulating from the start of the machine until it is turned off or reset. The high-precision sensor is installed on the working pressure pipeline of the venturi tube, connected to the PLC through a 4-20mA current signal or an RS485 communication interface, and monitors the working pressure in real time. The flow sensor is also a high-precision sensor, installed on the flow pipeline of the venturi tube, connected to the PLC through the same communication method, and monitors the working flow in real time. The control program is written in the PLC using a structured text language to realize functions such as data acquisition, processing, alarm judgment and data storage. The sampling frequency of the sensor data is set to once per second to ensure the real-time and accuracy of the data. The pressure alarm threshold is set to 2-4bar. When the working pressure exceeds this range, the PLC will trigger an alarm. The flow alarm threshold is set to 20-60L / min. When the working flow exceeds this range, an alarm is also triggered. When the PLC is turned on, the accumulated working timer is automatically cleared to ensure accurate timing. The pressure sensor and flow sensor are zero-calibrated to ensure that the output value of the sensor is accurate when there is no pressure or no flow. The sensor is calibrated at full scale to ensure that the output value of the sensor is consistent with the actual value at the maximum pressure or maximum flow.

[0116] The PLC collects data from the pressure sensor and flow sensor in real time and reads the output value of the sensor through the communication interface. Based on the collected data, the PLC calculates the current working pressure and flow of the Venturi tube. The calculation formula is as follows:

[0117] Current working pressure P = k p ×(V p -V p0 ), where k p Indicates the calibration coefficient of the pressure sensor; V p Indicates the current output value of the pressure sensor; V p0 Indicates the zero-point output value of the power sensor.

[0118] Current flow Q = k q ×(V q -V q0 ), where k q Indicates the calibration coefficient of the flow sensor; V q Indicates the current output value of the flow sensor; V q0 Indicates the zero output value of the flow sensor.

[0119] The current working pressure and flow rate are compared with the preset alarm thresholds. If they are out of range, the PLC will trigger an alarm and take corresponding control measures, such as shutting down and sending alarm information. When the Venturi tube starts working, the cumulative working timer in the PLC starts timing and records the actual working time of the Venturi tube. The PLC stores the real-time monitored data (including working pressure, flow rate, working time, etc.) in the internal memory and uploads it to the remote server through the Ethernet interface to achieve remote storage and backup of data. A data query interface is provided, and users can remotely query historical data through web pages or client software to analyze the working status and service life of the Venturi tube.

[0120] For example, when the PLC is turned on, the cumulative working timer is reset and the sensor is calibrated. When the system is running, the PLC collects sensor data in real time and calculates the current working pressure of the Venturi tube as 3 bar and the flow rate as 45 L / min. Since the current working pressure and flow rate are within the alarm threshold range, the system does not issue an alarm. When the Venturi tube continues to work for 120 minutes, the PLC records and stores the relevant data and uploads it to the remote server through the Ethernet interface.

[0121] In a preferred embodiment of the present invention, the above step 15, when it is detected that the wear of the venturi tube reaches a preset threshold, automatically adjust the powder injection gas volume; if it is predicted that the venturi tube is approaching the service life limit, automatically issue a warning instruction, may include:

[0122] Step 151, determining a preset threshold value and a service life limit of the venturi tube wear, and initializing relevant parameters of the wear monitoring system, including a cumulative working time counter and a wear amount estimation value;

[0123] Step 152, obtaining working status data in real time, including pressure and flow, through the sensor on the venturi tube;

[0124] Step 153, updating the working time count of the cumulative working time counter according to the working state data and the wear prediction model to calculate the estimated value of the wear amount of the current venturi tube;

[0125] Step 154, comparing the current estimated value of the wear of the Venturi tube with a preset wear threshold, if the current estimated value of the wear of the Venturi tube is greater than or equal to the wear threshold, the powder injection gas volume is automatically adjusted to compensate for the reduction in powder output due to wear;

[0126] Step 155, using the wear prediction model, the estimated value of the wear amount of the current venturi tube and the working time count, predict the remaining life of the venturi tube, if the predicted remaining life is ≤ the preset life limit, issue a warning instruction.

[0127] In an embodiment of the present invention, the wear threshold is set to 0.5mm, indicating that when the wear reaches or exceeds this value, the powder output will be affected. The service life limit is set to 2000 hours, indicating the maximum service life that the Venturi tube is expected to achieve under normal working conditions. Cumulative working time counter: initialized to 0 hours. The wear estimate is initialized to 0mm. The sensor data sampling frequency is set to once per second to ensure the real-time and accuracy of the data. The working status data is acquired in real time, and the pressure sensor data assumes that the real-time data is 3bar. The flow sensor data assumes that the real-time data is 45L / min. The current wear estimate is calculated based on the wear prediction model (assuming a linear model). The model takes into account factors such as working pressure, flow and working time. The wear estimate calculation formula is: W e =k1·P+k2·Q+k3·T; where k1, k2, k3 are coefficients; P is the working pressure; Q is the flow rate; Q is the working time.

[0128] Assume that the model predicts that under the current working conditions, the venturi tube can still be used for 500 hours (this is an assumed value). Calculate the difference between the service life limit and the current working time: 2000-1500=500 hours. Compare the predicted remaining life (500 hours) with the difference between the service life limit and the current working time (500 hours). Since the two are equal, no warning command is issued. However, if the predicted remaining life ≤ the difference between the service life limit and the current working time, the control system will automatically issue a warning command.

[0129] By real-time monitoring of the wear of the Venturi tube and automatically adjusting the powder injection volume when the preset threshold is reached, the powder output can be ensured to remain stable and avoid the reduction of powder output due to wear, thereby improving the quality and efficiency of the spraying operation. Through accurate wear monitoring and timely adjustment of the powder injection gas volume, the damage of the Venturi tube caused by excessive wear can be reduced, thereby extending its service life, reducing the replacement frequency and maintenance costs. By predicting the remaining life of the Venturi tube and automatically issuing early warning instructions when it is close to the service life limit, measures can be taken in advance to replace the severely worn Venturi tube, avoid sudden failures caused by wear, and ensure the continuity and stability of the spraying operation. The entire monitoring and management process is automatically completed by the control system without manual intervention, which improves the automation level of the spraying operation, reduces the burden on operators, and reduces errors and failures caused by human factors. By real-time monitoring and prediction of the wear and remaining life of the Venturi tube, maintenance plans can be made more accurately to avoid unnecessary replacement and repair, thereby optimizing resource utilization and reducing operating costs.

[0130] In another preferred embodiment of the present invention, according to the early warning instruction, a new venturi tube is replaced, and the life prediction and automatic compensation settings are updated according to the state of the new venturi tube to monitor and predict the wear of the new venturi tube in real time, which may include:

[0131] In an embodiment of the present invention, the control system automatically issues an early warning instruction when it detects through a sensor that the wear of the venturi tube is close to or reaches the service life limit. After receiving the early warning information, the operator prepares to perform a replacement operation. The operator presses the stop button of the sprayer to stop the sprayer to ensure safety. The operator removes the worn venturi tube from the sprayer according to the prescribed disassembly process. The operator checks whether the model and specifications of the new venturi tube match the original tube. The new venturi tube is correctly installed on the sprayer, and ensures that the connection is tight and there is no leakage. Find and click the "Reset" button on the user interface of the sprayer controller. The control system performs a reset operation, including clearing the cumulative working timer and resetting the cumulative working time to 0 hours. Reset the relevant parameters of the wear prediction model to start monitoring the wear of the new venturi tube. Reset the settings of the automatic compensation logic to ensure that the adjustment of the powder injection gas volume is based on the new wear state in the early stage of use of the new venturi tube.

[0132] The control system obtains the working pressure, flow and other status information of the new Venturi tube in real time through sensors. According to the material properties, design specifications and historical usage data (if any) of the new Venturi tube, adjust the parameters of the life prediction model. These parameters include wear rate coefficient, working pressure and flow rate influence coefficient on wear, etc. According to the wear characteristics and expected service life of the new Venturi tube, adjust the settings of the automatic compensation logic. Set a new wear threshold. When the wear reaches or exceeds this value, the control system will automatically adjust the powder injection gas volume to compensate for the reduction in powder output. Adjust the adjustment amplitude and frequency of the powder injection gas volume to ensure that the powder output remains stable during the use of the new Venturi tube.

[0133] Assume that in a sprayer system, the wear threshold of the venturi tube is set to 0.5mm and the service life limit is 2000 hours. When the control system detects that the wear of the current venturi tube has reached 0.48mm and predicts that the remaining life is less than 20 hours, it issues an early warning instruction. After receiving the early warning, the operator stops the sprayer, removes the worn venturi tube, and installs a new one. Then, click the "Reset" button on the user interface of the sprayer controller, and the control system performs the reset operation. After that, the control system starts to obtain the status information of the new venturi tube in real time, and updates the parameters of the life prediction model and the settings of the automatic compensation logic based on this information. Assuming that the material properties of the new venturi tube are similar to those of the old tube, but the design is improved, the service life is expected to be extended to 2500 hours. Therefore, the operator updates the service life limit to 2500 hours and adjusts the wear threshold and the adjustment settings of the powder injection gas volume accordingly.

[0134] By responding to the early warning instructions in time and replacing the worn venturi tube, the interruption of the spraying operation caused by the failure of the venturi tube can be avoided, thereby ensuring the continuity and production efficiency of the operation. The newly installed venturi tube has better flow characteristics and wear performance, which can ensure the uniform distribution of powder during the spraying process and improve the spraying quality and product consistency. By updating the relevant parameters of the life prediction model, the control system can more accurately monitor the wear of the new venturi tube and perform maintenance or replacement at the appropriate time, thereby extending the service life of the entire spraying system. After resetting the cumulative working timer and the wear prediction model, the control system can optimize the automatic compensation of the powder injection gas volume based on the actual use of the new venturi tube to avoid waste and optimize resource utilization. By monitoring and predicting the wear of the new venturi tube in real time, a more accurate maintenance plan can be formulated to reduce the maintenance cost and downtime caused by sudden failures. The entire process, from early warning to replacement to resetting and updating settings, can be automatically completed or assisted by the control system, which improves the automation level of the spraying operation and reduces the burden on operators. By updating the settings of the automatic compensation logic, the control system can better adapt to the characteristics of the new Venturi tube, ensuring the best spraying effect under different working conditions.

[0135] like Figure 2 As shown, an embodiment of the present invention further provides a Venturi tube wear automatic compensation warning system 20, characterized in that it includes:

[0136] The acquisition module 20 is used to establish a finite element model of the Venturi tube and define the properties of the Venturi tube material in the finite element model, including elastic modulus, Poisson's ratio, and density parameters; perform finite element analysis based on the finite element model to obtain finite element analysis results, and determine the key areas and potential failure modes of wear of the Venturi tube during operation based on the finite element analysis results; establish a wear prediction model based on the results of the finite element analysis and historical usage data to predict the wear of the Venturi tube under different working conditions;

[0137] The processing module 22 is used to calculate the wear of the Venturi tube in real time according to the wear prediction model and the working state of the Venturi tube, and dynamically display the wear status and predict the remaining life information on the user interface; when it is detected that the wear of the Venturi tube reaches a preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the Venturi tube is close to the service life limit, a warning instruction is automatically issued.

[0138] like Figure 3 As shown, an embodiment of the present invention further provides a spraying machine controller, comprising:

[0139] The powder pump body 3 is in the shape of a rectangular parallelepiped;

[0140] A powder injection nozzle 2, one end of which extends into the inside of the powder pump body 3;

[0141] A spray gun powder delivery pipe 6 is arranged on one side of the powder pump body 3;

[0142] The venturi tube 1 has one end extending into the powder pump body 3 and the other end extending into the powder delivery pipe 6 of the spray gun, and a limiting portion is provided in the middle of the venturi tube 1, and the two sides of the limiting portion press against the powder pump body 3 and the powder delivery pipe 6 of the spray gun respectively;

[0143] A powder extraction pipe 5 is connected to the powder pump body 3 to extract powder from a powder source and transport the powder into the powder pump body 3;

[0144] The powder pump seat 4 is used to support and fix the powder pump body 3 and the powder extraction tube 5 .

[0145] In an embodiment of the present invention, the powder extraction tube 5 is connected to the powder source, and the powder is extracted from the powder source by the mechanical force inside the tube, and is transported to the powder pump body 3. The powder pump body 3 serves as a temporary storage and transportation space for the powder, and plays the role of a powder transfer station. One end of the venturi tube 1 extends into the powder pump body 3, and the other end extends into the spray gun powder delivery tube 6. When the powder injection nozzle 2 injects a high-speed airflow into the venturi tube 1, according to the venturi effect, the airflow forms a low-pressure area in the venturi tube 1, thereby attracting the powder in the powder pump body 3 into the venturi tube 1, and mixing with the airflow to form a powder airflow. The mixed powder airflow enters the spray gun powder delivery tube 6 through the venturi tube 1, and is finally sprayed out by the spray gun to realize the spraying operation. The limiter design in the middle of the venturi tube 1 ensures its stable position between the powder pump body 3 and the spray gun powder delivery tube 6, and ensures the smooth transportation of the powder airflow. The powder pump seat 4 is used to support and fix the powder pump body 3 and the powder extraction pipe 5, thereby ensuring the stability and reliability of the entire spray machine controller.

[0146] Through the Venturi effect, efficient mixing of powder and airflow is achieved, and the spraying efficiency and quality are improved. The design of the limiting part in the middle of the Venturi tube 1, and the support and fixation of the powder pump body 3 and the powder extraction tube 5 by the powder pump seat 4 ensure the stability and reliability of the entire sprayer controller, and reduce the spraying problems caused by loose components or position displacement. The structural design of the sprayer controller is reasonable, and the connection between the components is tight and easy to disassemble, which is convenient for users to perform daily maintenance and replace worn parts. The sprayer controller can be applied to different types of powders and spraying requirements. By adjusting the air flow velocity of the powder injection nozzle 2 and the design of the Venturi tube 1, flexible adjustment of different spraying effects can be achieved.

[0147] like Figure 3 As shown, a cumulative working timer 7 is provided in the powder pump body 3. When the powder pump body 3 is working, the time is automatically counted, and when it is not working, the cumulative working timer 3 is saved when the power is turned off and continues to count when the power is turned on next time.

[0148] In the embodiment of the present invention, when the powder pump body 3 starts to work (for example, when the powder extraction pipe 5 starts to extract powder and transport it into the powder pump body 3, or when the powder injection nozzle 2 injects air flow into the venturi tube 1), the cumulative working timer 7 automatically starts timing. If the powder pump body 3 is in a non-working state (for example, the spraying operation is paused or stopped), the cumulative working timer 7 will not count, thereby ensuring the accuracy of the timing. The cumulative working timer 7 also has a power-off saving function, that is, when the sprayer controller is powered off, the data inside the timer (such as the cumulative working time) will be saved. When the sprayer controller is powered on again, the cumulative working timer 7 will continue to count from the last saved data, thereby ensuring the continuity and accuracy of the cumulative working time.

[0149] Through the automatic timing and power-off saving functions of the cumulative working timer 7, the actual working time of the powder pump body 3 can be accurately recorded, providing an accurate basis for the user's maintenance and replacement of parts. The user can maintain the powder pump body 3 and replace worn parts in time according to the time displayed by the cumulative working timer 7, thereby improving the maintenance efficiency and service life of the sprayer. The continuous timing function of the cumulative working timer 7 eliminates the need for the user to reset or record the working time every time, thereby optimizing the user experience. By accurately recording the working time of the powder pump body 3, the user can promptly discover and prevent potential failures caused by long-term work, thereby ensuring the smooth progress of the spraying operation.

[0150] It should be noted that the system is a system corresponding to the above method, and all implementation methods in the above method embodiment are applicable to this embodiment and can achieve the same technical effect.

[0151] The embodiment of the present invention further provides a computing device, comprising: a processor, a memory storing a computer program, wherein when the computer program is executed by the processor, the method described above is executed. All implementations in the above method embodiment are applicable to this embodiment and can achieve the same technical effect.

[0152] The embodiment of the present invention also provides a computer-readable storage medium storing instructions, which, when executed on a computer, enable the computer to execute the method described above. All implementations in the above method embodiment are applicable to this embodiment and can achieve the same technical effect.

[0153] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A Venturi tube wear automatic compensation early warning method, characterized in that: The method comprises: Establishing a finite element model of the venturi tube, and defining the properties of the venturi tube material in the finite element model, wherein the properties of the venturi tube material include elastic modulus, Poisson's ratio, and density parameter; According to the finite element model, finite element analysis is performed to obtain finite element analysis results, and according to the finite element analysis results, the key areas and potential failure modes of the venturi tube that may cause wear during operation are determined; Based on the results of finite element analysis and historical usage data, a wear prediction model is established to predict the wear of the Venturi tube under different working conditions; According to the wear prediction model and the working status of the Venturi tube, the wear condition of the Venturi tube is calculated in real time, and the wear condition and the predicted remaining life information are dynamically displayed on the user interface; When it is detected that the wear of the Venturi tube reaches a preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the Venturi tube is approaching the service life limit, an early warning command is automatically issued.

2. The Venturi tube wear automatic compensation early warning method according to claim 1, characterized in that: According to the finite element model, finite element analysis is performed to obtain finite element analysis results, and based on the finite element analysis results, the key areas and potential failure modes of wear of the venturi tube during operation are determined, including: Mesh the finite element model of the Venturi tube and set boundary conditions and loads, including inlet and outlet pressure, flow conditions, and temperature loads; Determine the solver and solve the finite element model of the Venturi tube. During the solving process, calculate the stress distribution and deformation of the finite element model under different working conditions; According to the stress distribution and deformation, the key areas where the Venturi tube wears during operation are analyzed and determined. According to the working conditions and material properties of the Venturi tube, the potential failure modes of the Venturi tube are evaluated, including fatigue failure, plastic deformation, and fracture.

3. The Venturi tube wear automatic compensation early warning method according to claim 2, characterized in that: Mesh the finite element model of the Venturi tube and set boundary conditions and loads, including pressure and flow conditions and temperature loads at the inlet and outlet, including: Import the finite element model of the Venturi tube into the finite element analysis software and determine the mesh type according to the geometric shape of the Venturi tube; According to the mesh type, determine the size and density of the mesh, identify the wear area and stress concentration area, and increase the mesh density in the wear area and stress concentration area; The finite element model of the Venturi tube is meshed according to the mesh type and mesh size, and boundary conditions and loads are set, including the pressure and flow conditions at the inlet and outlet, as well as the temperature load.

4. The automatic compensation and early warning method for Venturi tube wear according to claim 3 is characterized in that: Based on the results of finite element analysis and historical usage data, a wear prediction model was established to predict the wear of the Venturi tube under different working conditions, including: From the finite element analysis results and historical usage data, collect the stress distribution, deformation, wear data of the Venturi tube under different working conditions, as well as the usage time and working condition records; Integrate finite element analysis data with historical usage data to obtain a dataset of venturi tube wear information; Extract characteristic variables related to the wear of the Venturi tube from the data set of the wear information of the Venturi tube, including working conditions, material properties, and use time; Using characteristic variables, a Venturi tube wear prediction model is constructed to predict the wear of the Venturi tube under different working conditions.

5. The Venturi tube wear automatic compensation early warning method according to claim 4, characterized in that: The calculation formula of the Venturi tube wear prediction model is: Among them, W represents the expected wear amount of the Venturi tube; a, b, c, d, e and f represent coefficients; g represents the bias term; T represents the working time of the Venturi tube; u represents the index of the working time T of the Venturi tube; P represents the pressure during the working process; m represents the index of the pressure P; Q represents the flow rate during the working process; M represents the material property; M0 represents the reference value of the material property; k represents the index of the material property M.

6. The Venturi tube wear automatic compensation early warning method according to claim 5, characterized in that: In the sprayer controller, the cumulative working timer is used to record the working time of the Venturi tube, and the working status of the Venturi tube is monitored in real time based on the sensor data, including pressure and flow.

7. The Venturi tube wear automatic compensation early warning method according to claim 6, characterized in that: When the wear of the Venturi tube reaches the preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the Venturi tube is approaching the service life limit, an early warning instruction is automatically issued, including: Determine preset thresholds and service life limits for venturi tube wear; The working status data, including pressure and flow, can be obtained in real time through the sensor on the Venturi tube; According to the working state data and the wear prediction model, the working time count of the cumulative working time counter is updated to calculate the estimated value of the wear amount of the current venturi tube; The estimated wear value of the current venturi tube is compared with the preset wear threshold. If the estimated wear value of the current venturi tube is ≥ the wear threshold, the powder injection gas volume will be automatically adjusted; The remaining life of the Venturi tube is predicted using the wear prediction model, the estimated value of the current wear of the Venturi tube and the working time count. If the predicted remaining life is ≤ the preset life limit, an early warning instruction is issued.

8. A Venturi tube wear automatic compensation warning system, the system implements the method according to claim 1, characterized in that: include: An acquisition module is used to establish a finite element model of the Venturi tube and define the properties of the Venturi tube material in the finite element model, including elastic modulus, Poisson's ratio, and density parameters; According to the finite element model, finite element analysis is performed to obtain finite element analysis results, and according to the finite element analysis results, the key areas and potential failure modes of the venturi tube that may cause wear during operation are determined; Based on the results of finite element analysis and historical usage data, a wear prediction model is established to predict the wear of the Venturi tube under different working conditions; The processing module is used to calculate the wear of the Venturi tube in real time according to the wear prediction model and the working status of the Venturi tube, and dynamically display the wear status and predict the remaining life information on the user interface; when it is detected that the wear of the Venturi tube reaches a preset threshold, the powder injection gas volume is automatically adjusted; if it is predicted that the Venturi tube is approaching the service life limit, a warning instruction is automatically issued.

9. A computing device, characterized in that include: one or more processors; A storage device for storing one or more programs, when the one or more programs are executed by the one or more processors, the one or more processors implement the method as claimed in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a program, which, when executed by a processor, implements the method according to any one of claims 1 to 7.

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