Full-automatic polyurea assembled tank production system and method

Abstract

The invention discloses a full-automatic polyurea assembled tank production system and method, and relates to the technical field of polyurea assembled tank production, related data before spraying of a polyurea assembled tank is obtained, and the related data before spraying of the polyurea assembled tank comprises spraying equipment data, spraying environment data, polyurea assembled tank base data and raw material data; relevant data before spraying of the polyurea assembled tank are detected, and whether polyurea coating spraying is triggered or not is recognized; based on the spraying parameters, polyurea coating spraying is controlled, and real-time monitoring is carried out; after spraying of the polyurea coating is completed, defect detection is carried out, and defect positions are identified and marked; automatically repairing the defect position according to the defect detection result, wherein the automatic repairing comprises coating repairing and abrasion repairing; and after spraying and repairing are completed, it is automatically confirmed that the production process is completed, and a production report is output. The automation of comprehensive detection before spraying and automatic defect identification and repair is realized, and the quality control and efficiency of polyurea assembled tank production are improved.

Description

Technical Field

[0001] The invention relates to the technical field of polyurea assembled tank production, and in particular to a full-automatic polyurea assembled tank production system and method. Background Art

[0002] Polyurea coatings are widely used in industrial protection, construction, transportation and other fields due to their excellent physical and chemical properties, such as excellent wear resistance, corrosion resistance and elasticity. With the improvement of coating quality and performance requirements, the market demand for polyurea coatings continues to increase, and polyurea materials are widely used in anti-corrosion, construction, transportation, storage tanks and pipelines. Especially in environments that require high durability and corrosion resistance, polyurea assembled tanks can effectively extend their service life. With the acceleration of industrialization, especially in the petroleum and chemical industries, the demand for polyurea assembled tanks continues to rise.

[0003] The production method of traditional polyurea assembled tanks often relies on manual labor, and manual detection of coating defects is inefficient and inaccurate. In addition, during the manual spraying process, differences in the skill levels of operators lead to inconsistent coating thickness and quality, which may cause coating defects. Most defects are discovered in the later stages of production, increasing the cost of repair. For the repair of existing defects, most rely on manual operations, and it is difficult to ensure that the coating thickness of the recoated area is consistent with the surrounding area, affecting the appearance and performance of the final product. In addition, existing technologies usually lack effective data collection and analysis mechanisms, making it difficult to obtain feedback from production data, affecting the optimization and improvement of subsequent production.

[0004] Therefore, in view of the above problems, there is an urgent need for a fully automatic polyurea assembly tank production system and method. Summary of the invention

[0005] In view of the deficiencies in the prior art, the present invention provides a fully automatic polyurea assembled tank production system and method, which solves the problems of insufficient pre-spraying detection and low defect correction efficiency in the production process of polyurea assembled tanks.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: a fully automatic polyurea assembled tank production system, comprising the following steps: a data acquisition module, used to acquire relevant data of the polyurea assembled tank before spraying, the relevant data of the polyurea assembled tank before spraying specifically includes spraying equipment data, spraying environment data, polyurea assembled tank substrate data and raw material data; a spraying preparation module, used to detect through the relevant data of the polyurea assembled tank before spraying, and identify whether the polyurea coating spraying is triggered; a spraying monitoring module, used to control the polyurea coating spraying based on the spraying parameters, and perform real-time monitoring during the polyurea coating spraying process; a spraying effect detection and defect recognition module, used to perform defect detection after the polyurea coating is sprayed, identify and mark the defect position; a defect repair module, used to automatically repair the defect position according to the defect detection result, and the automatic repair includes touch-up repair and wear repair; a production completion module, used to automatically confirm the completion of the production process based on the completion of spraying and repair, and output a production report.

[0007] Furthermore, the spraying equipment data specifically includes the spray gun movement speed and the equipment operation vibration level; the spraying environment data specifically includes the construction temperature and the construction humidity; the polyurea assembly tank substrate data specifically includes the substrate surface roughness and the substrate surface cleanliness; the raw material data specifically includes the raw material mixing ratio and the raw material flow rate.

[0008] Furthermore, the specific analysis of the detection of relevant data before spraying of the polyurea assembled tank is as follows: obtaining the preset parameters of the polyurea assembled tank before spraying, wherein the preset parameters of the polyurea assembled tank before spraying specifically include a preset range of spray gun movement speed, a preset range of equipment vibration level, a preset range of construction temperature, a preset range of construction humidity, a preset range of substrate surface roughness, a preset range of substrate surface cleanliness, a preset mixing ratio of raw materials, and a preset range of raw material flow speed; comparing the spray gun movement speed and the equipment operation vibration level with the preset range of spray gun movement speed and the preset range of equipment vibration level, respectively; when the injection pressure is within the preset range of injection pressure, and the spray gun movement speed is within the preset range of spray gun movement speed, and the equipment operation vibration level is within the preset range of equipment vibration level, marking the spray equipment inspection as qualified; comparing the construction temperature and construction The humidity is compared with the preset range of construction temperature and the preset range of construction humidity respectively. When the construction temperature is within the preset range of construction temperature and the construction humidity is within the preset range of construction humidity, the spray environment test is marked as qualified; the substrate surface roughness and the substrate surface cleanliness are compared with the preset range of substrate surface roughness and the preset range of substrate surface cleanliness respectively. When the substrate surface roughness is within the preset range of substrate surface roughness and the substrate surface cleanliness is within the preset range of substrate surface cleanliness, the polyurea assembly tank substrate test is marked as qualified; the raw material mixing ratio and the raw material flow rate are compared with the preset mixing ratio of raw materials and the preset range of raw material flow rate respectively. When the raw material mixing ratio meets the preset mixing ratio of raw materials and the raw material flow rate is within the preset range of raw material flow rate, the raw material test is marked as qualified.

[0009] Furthermore, the specific identification method of whether to trigger the polyurea paint spraying is: identifying the spraying equipment, spraying environment, polyurea assembly tank base and raw material detection status, when the spraying equipment detection is qualified, the spraying environment detection is qualified, the polyurea assembly tank base detection is qualified, and the raw material detection is qualified, the polyurea paint spraying is triggered.

[0010] Furthermore, the control of polyurea coating spraying based on spraying parameters is specifically as follows: obtaining spraying parameters, and controlling and adjusting in real time based on the spraying parameters during the polyurea coating spraying process, wherein the spraying parameters specifically include spraying distance, spraying angle and injection pressure; the real-time control and adjustment is specifically as follows: obtaining actual spraying distance, actual injection angle and actual injection pressure in real time, and when the actual spraying distance, actual injection angle and actual injection pressure deviate from the spraying distance, spraying angle and injection pressure in the injection parameters, adjusting the deviation data in real time.

[0011] Furthermore, defect detection is performed on the polyurea coating after spraying, and the specific analysis of identifying and marking the defect position is as follows: based on the defect detection equipment, the surface image of the polyurea assembled tank is obtained, and the surface image of the polyurea assembled tank is preprocessed, and the preprocessing includes removing background noise, image grayscale processing and image segmentation; the edge detection algorithm is used to identify the edge of the coating surface, and the texture analysis method is used to detect the uniformity and smoothness of the coating, and then the defects and positions in the surface image of the polyurea assembled tank are identified based on the defect model; the identified defects are classified, and the surface position coordinates of each defect on the polyurea assembled tank are marked, and the specific classifications include pinhole defects, concave defects and convex defects.

[0012] Furthermore, the specific analysis of the automatic repair of the defect position according to the defect detection result is as follows: for the pinhole defect and the concave defect, repainting repair is performed, and the specific steps of the repainting repair are as follows: the defect depth and defect width of the pinhole defect and the concave defect are obtained, the wind speed during repainting repair is identified, and the wind speed is compared with the spraying wind speed threshold. When the wind speed is less than or equal to the wind speed threshold, the amount of repainted polyurea coating is obtained based on the defect depth and defect width, and then repainting repair is performed based on the amount of repainted polyurea coating and the surface position coordinates of the pinhole defect or the concave defect on the polyurea assembly tank; when the wind speed is greater than the wind speed threshold, an alarm mechanism is used to prompt the construction personnel to perform manual windproof spraying; for the convex defect, abrasion repair is performed, and the specific steps of abrasion repair are as follows: the convex height, convex width and convex length of the convex defect are obtained, the convex boundary is marked according to the convex height, convex width and convex length of the convex defect, and the convex defect is automatically abraded until the abrasion touches the convex boundary, and the abrasion is stopped.

[0013] A fully automatic polyurea assembled tank production method, using the above-mentioned fully automatic polyurea assembled tank production system, includes the following steps: obtaining relevant data of the polyurea assembled tank before spraying, the relevant data of the polyurea assembled tank before spraying specifically includes spraying equipment data, spraying environment data, polyurea assembled tank base data and raw material data; detecting through the relevant data of the polyurea assembled tank before spraying, and identifying whether the polyurea coating spraying is triggered; controlling the polyurea coating spraying based on the spraying parameters, and performing real-time monitoring during the polyurea coating spraying process; performing defect detection after the polyurea coating is sprayed, identifying and marking the defect position; automatically repairing the defect position according to the defect detection result, the automatic repair includes touch-up repair and wear repair; automatically confirming the completion of the production process after the spraying and repair are completed, and outputting a production report.

[0014] The present invention has the following beneficial effects:

[0015] The fully automatic polyurea assembled tank production system and method, through the automated process, from data acquisition, spraying control, real-time monitoring to defect detection and automatic repair, the whole process is highly automated and intelligent, reducing the manual operation link, thereby significantly improving production efficiency and shortening the production cycle; in the spraying process, by real-time monitoring of spraying parameters, the stability and consistency of spraying quality can be ensured; the defect detection link can timely discover and mark the defect position in the spraying process, providing accurate information for subsequent automatic repair; the automatic repair function can accurately perform repainting repair or wear repair on the defect position, thereby ensuring the overall quality of the product; through precise spraying control and defect repair, the waste of raw materials is reduced, the production cost is reduced, the spraying parameters and repair strategies can be flexibly adjusted according to different spraying requirements, suitable for the production of polyurea assembled tanks of different specifications and shapes, and the flexibility and adaptability of production are enhanced; the fully automated production method demonstrates the company's technical strength and modern management level, reduces energy consumption and emissions in the production process, and meets the requirements of modern society for green and sustainable development.

[0016] Of course, any product implementing the present invention does not necessarily need to achieve all of the advantages described above at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a structural diagram of a fully automatic polyurea assembly tank production system of the present invention.

[0018] Figure 2 The present invention is a method flow chart of a fully automatic polyurea assembly tank production system. DETAILED DESCRIPTION

[0019] The embodiment of the present application realizes automation of comprehensive inspection before spraying and automatic identification and repair of defects through a fully automatic polyurea assembled tank production system and method, thereby improving the quality control and efficiency of polyurea assembled tank production.

[0020] The overall idea of ​​the problem in the embodiment of this application is as follows:

[0021] Before production begins, data on spraying equipment, conditions, base materials and raw materials are collected to ensure that basic information for production is complete; based on previously acquired data and set spraying parameters, the spraying of polyurea coatings is automatically controlled to improve the consistency and quality of the coating; after spraying, coating defects are automatically detected and defect locations are marked to provide a basis for subsequent repairs; for detected defects, the system automatically selects appropriate repair methods (re-coating or abrasion) to ensure that the quality of the final product meets the standards; the entire spraying and repair process is monitored to ensure that each step meets the preset standards; after production is completed, a report is automatically generated to record key parameters, defects and repair measures in the production process.

[0022] See also Figure 1 The embodiment of the present invention provides a technical solution: a fully automatic polyurea assembled tank production system, comprising the following steps: a data acquisition module, used to acquire relevant data of the polyurea assembled tank before spraying, the relevant data of the polyurea assembled tank before spraying specifically includes spraying equipment data, spraying environment data, polyurea assembled tank substrate data and raw material data; a spraying preparation module, used to detect through the relevant data of the polyurea assembled tank before spraying, and identify whether to trigger the spraying of polyurea coating; a spraying monitoring module, used to control the spraying of polyurea coating based on spraying parameters, and perform real-time monitoring during the spraying process of polyurea coating; a spraying effect detection and defect recognition module, used to perform defect detection after the polyurea coating is sprayed, identify and mark the defect position; a defect repair module, used to automatically repair the defect position according to the defect detection result, and the automatic repair includes repainting repair and wear repair; a production completion module, used to automatically confirm the completion of the production process based on the completion of spraying and repair, and output a production report.

[0023] Specifically, the spraying equipment data specifically includes the spray gun movement speed and the equipment operation vibration level; the spraying environment data specifically includes the construction temperature and construction humidity; the polyurea assembly tank base data specifically includes the base surface roughness and the base surface cleanliness; the raw material data specifically includes the raw material mixing ratio and the raw material flow rate.

[0024] In this embodiment, the movement speed of the spray gun indicates the deposition rate of the coating and the uniformity of the coating during the spraying process, which can ensure the uniformity of the coating and avoid overspraying or inconsistent coating thickness. A speed sensor or encoder is embedded in the spray gun system to monitor the movement speed in real time for acquisition; the equipment operation vibration level indicates the stability and accuracy of the equipment operation. Acquiring the equipment operation vibration level can reduce the coating defects caused by vibration of the equipment, thereby improving the spraying quality. The vibration frequency and amplitude of the equipment during operation are monitored by the vibration sensor for acquisition; the construction temperature indicates the environmental conditions that affect the chemical reaction and curing of the coating, which can control the drying time and adhesion of the coating and avoid coating defects caused by excessively high or low temperatures. The temperature of the construction environment is monitored in real time using a temperature sensor (such as PT100 or thermocouple) for acquisition; the construction humidity indicates the moisture content in the environment, which affects the drying and curing process of the coating, affects the fluidity and adhesion of the coating, and ensures the quality of the coating. A humidity sensor (such as humidity The surface roughness of the substrate indicates the physical properties of the substrate surface, which affects the adhesion of the coating and the overall coating effect. A surface with appropriate roughness helps to improve the adhesion strength of the coating. It is measured and obtained using a roughness meter or a three-dimensional laser scanner. The surface cleanliness of the substrate indicates whether there are impurities on the surface that affect the quality of the coating, so as to avoid pollutants and oil stains that affect the adhesion of the coating and ensure the quality of the coating. It is obtained by evaluating the cleanliness of the substrate surface through a visual inspection system or a cleanliness testing instrument. The mixing ratio of raw materials indicates the chemical composition of the raw materials, which directly affects the performance of the coating, ensures the completeness of the chemical reaction, and avoids coating defects caused by improper ratios. It is obtained by monitoring the mixing ratio of raw materials using an electronic scale or flow meter. The flow rate of raw materials indicates the fluidity of the raw materials during the transportation process, which affects the stability and uniformity of the coating during spraying and ensures the quality of spraying. It is obtained by monitoring the flow rate of raw materials through a flow sensor or a pressure sensor.

[0025] Specifically, the specific analysis of the detection of relevant data before spraying of the polyurea assembled tank is as follows: obtaining the preset parameters of the polyurea assembled tank before spraying, which specifically include the preset range of spray gun movement speed, the preset range of equipment vibration level, the preset range of construction temperature, the preset range of construction humidity, the preset range of substrate surface roughness, the preset range of substrate surface cleanliness, the preset mixing ratio of raw materials, and the preset range of raw material flow speed; comparing the spray gun movement speed and the equipment operation vibration level with the preset range of spray gun movement speed and the preset range of equipment vibration level respectively. When the injection pressure is within the preset range of injection pressure, the spray gun movement speed is within the preset range of spray gun movement speed, and the equipment operation vibration level is within the preset range of equipment vibration level, the spray equipment is marked as qualified; the construction temperature and construction humidity are respectively compared with the preset range of spray gun movement speed and the preset range of equipment vibration level. Compare with the preset range of construction temperature and the preset range of construction humidity respectively. When the construction temperature is within the preset range of construction temperature and the construction humidity is within the preset range of construction humidity, mark the spray environment test as qualified; compare the substrate surface roughness and the substrate surface cleanliness with the preset range of substrate surface roughness and the preset range of substrate surface cleanliness respectively. When the substrate surface roughness is within the preset range of substrate surface roughness and the substrate surface cleanliness is within the preset range of substrate surface cleanliness, mark the polyurea assembly tank substrate test as qualified; compare the raw material mixing ratio and the raw material flow rate with the preset mixing ratio of raw materials and the preset range of raw material flow rate respectively. When the raw material mixing ratio meets the preset mixing ratio of raw materials and the raw material flow rate is within the preset range of raw material flow rate, mark the raw material test as qualified.

[0026] In this implementation scheme, the preset range of the spray gun movement speed is set according to the material characteristics and spraying process requirements, and the optimal spraying speed is determined, or a reasonable range is established through experiments and historical data analysis; the setting of the preset range of the equipment vibration level depends on the standards and industry specifications of the equipment manufacturer, and the allowable vibration range of the equipment during operation is set; the setting of the preset range of construction temperature and humidity is based on the physical and chemical properties of the polyurea material, and suitable construction conditions are set to ensure that the material can be well cured; the setting of the preset range of the substrate surface roughness and cleanliness is determined through material science research and coating adhesion testing to determine the standard requirements for substrate treatment; the raw material mixing ratio is determined according to the material formula and the optimal mixing ratio is determined in combination with experimental data to ensure performance optimization; the setting of the preset range of the raw material flow rate refers to the material characteristics and the spraying equipment capabilities, and the optimal range of fluidity is set to ensure the stability of the spraying process.

[0027] Through detailed testing, we ensure that each spraying process is carried out under the best conditions, reduce defects and improve coating consistency; timely detect unqualified parameters to avoid unnecessary spraying and subsequent returns, saving time and resources; through automated testing, reduce manual intervention and judgment, and improve the overall efficiency of the production line; monitor the construction environment and equipment status to reduce safety hazards caused by equipment failure or unsuitable environment; collect and analyze parameter data before spraying to provide a basis for future process improvements and promote continuous improvement.

[0028] Specifically, the specific identification method for identifying whether to trigger the polyurea paint spraying is: identifying the spraying equipment, spraying environment, polyurea assembly tank base and raw material inspection status. When the spraying equipment inspection is qualified, the spraying environment inspection is qualified, the polyurea assembly tank base inspection is qualified, and the raw material inspection is qualified, the polyurea paint spraying is triggered.

[0029] In this implementation scheme, comprehensive inspections of the spraying equipment environment, substrate and raw materials ensure that each link meets the standards, thereby greatly improving the quality and consistency of the coating; parameter comparisons before spraying can effectively prevent defects that may occur during the spraying process, such as pinholes and concave defects, and reduce the cost of subsequent repairs; automated detection and identification mechanisms can quickly determine whether spraying conditions are met, avoiding the time and errors of manual inspections and improving production efficiency; collection and analysis of preset parameters can provide data support for subsequent improvements and optimizations, promoting continuous improvement of production processes; ensuring that the materials and conditions used in the spraying process are consistent, thereby ensuring that the thickness and color of the coating are coordinated with the surrounding area.

[0030] Specifically, controlling the spraying of polyurea coating based on spraying parameters comprises: obtaining spraying parameters, and controlling and adjusting in real time based on the spraying parameters during the spraying process of polyurea coating, the spraying parameters specifically include spraying distance, spraying angle and injection pressure; real-time control and adjustment comprises: obtaining the actual spraying distance, actual injection angle and actual injection pressure in real time, and when the actual spraying distance, actual injection angle and actual injection pressure deviate from the spraying distance, spraying angle and injection pressure in the injection parameters, adjusting the deviation data in real time.

[0031] In this embodiment, the spraying distance is determined based on historical data and small-scale spraying experiments to obtain the best spraying distance. Usually, multiple test sprays are carried out within a certain range to determine the optimal distance for setting. The corresponding spraying distance can also be set according to the technical specifications of the spraying equipment to ensure that the paint can be evenly sprayed on the target surface; the spraying angle is set according to the specific shape and structure of the polyurea assembly tank to ensure that the paint can cover all difficult-to-reach areas. The design characteristics of the nozzle can also be considered to adjust the spraying angle to obtain the best spray effect; the injection pressure is set according to the viscosity and fluidity of the polyurea paint. The optimal pressure is determined by test spraying to ensure a good atomization effect of the paint. The injection pressure can also be set within a reasonable range based on the maximum bearing capacity of the spraying equipment to ensure stable operation of the equipment. The dynamic adjustment in actual operation uses high-precision sensors to monitor the spraying distance, angle and pressure in real time to ensure the accuracy of the data. When the actual parameters are monitored to deviate from the set spraying parameters, the feedback system automatically adjusts the spraying equipment to restore it to the set parameter range.

[0032] Real-time monitoring and spraying parameters can ensure uniform coverage of the paint, thereby improving the quality and consistency of the coating; optimized spraying parameters can reduce excessive use of paint and reduce production costs; dynamic adjustment of spraying parameters can reduce downtime or re-spraying due to parameter deviations and improve overall production efficiency; according to different products or coating requirements, spray settings can be quickly adjusted to meet the requirements of diversified production; through real-time adjustment, coating defects caused by parameter deviations, such as unevenness, missed spraying or over-spraying, can be effectively avoided, thereby improving the quality of the final product.

[0033] Specifically, defect detection is performed on the polyurea coating after spraying, and the specific analysis of identifying and marking the defect position is as follows: the surface image of the polyurea assembled tank is obtained based on the defect detection equipment, and the surface image of the polyurea assembled tank is preprocessed, and the preprocessing includes removing background noise, image grayscale processing and image segmentation; the edge detection algorithm is used to identify the edge of the coating surface, and the texture analysis method is used to detect the uniformity and smoothness of the coating, and then the defects and positions in the surface image of the polyurea assembled tank are identified based on the defect model; the identified defects are classified, and the surface position coordinates of each defect on the polyurea assembled tank are marked, and the specific classifications include pinhole defects, concave defects and convex defects.

[0034] In this implementation scheme, through automatic detection of coating defects, problems can be discovered in a timely manner, the quality of polyurea assembled tanks can be ensured, and the production of unqualified products can be reduced; defect detection reduces the need for manual inspection, improves detection efficiency, and reduces the possibility of human error; by marking the specific location of defects on the surface, subsequent repair work is facilitated, and repair efficiency and accuracy are improved; defect detection data can be used for subsequent analysis and improvement, helping to optimize the spraying process and improve product quality.

[0035] Defect model recognition is based on pre-defined defect models (such as pinholes, depressions, and protrusions). Learning or deep learning algorithms (such as convolutional neural networks) are used to analyze the features of each area in the image to identify the defect type and its location. By continuously collecting defect detection data, the defect model can be iteratively updated to improve recognition accuracy and efficiency.

[0036] Specifically, the specific analysis of automatic repair of defect positions according to defect detection results is as follows: for pinhole defects and concave defects, touch-up repair is performed, and the specific steps of touch-up repair are as follows: the defect depth and defect width of the pinhole defects and concave defects are obtained, the wind speed during touch-up repair is identified, and the wind speed is compared with the spraying wind speed threshold. When the wind speed is less than or equal to the wind speed threshold, the amount of touch-up polyurea coating is obtained based on the defect depth and defect width, and then touch-up repair is performed based on the amount of touch-up polyurea coating and the surface position coordinates of the pinhole defect or concave defect on the polyurea assembly tank; when the wind speed is greater than the wind speed threshold, an alarm mechanism is used to prompt construction personnel to perform manual windproof spraying; for convex defects, wear-out repair is performed, and the specific steps of wear-out repair are as follows: the convex height, convex width and convex length of the convex defect are obtained, the convex boundary is marked according to the convex height, convex width and convex length of the convex defect, and the convex defect is automatically worn out until the wear touches the convex boundary, and the wear is stopped.

[0037] In this embodiment, the defect depth of pinhole defects and concave defects is obtained by measuring the depth of the defects in real time using a laser altimeter or ultrasonic measuring equipment; the width is obtained by analyzing the lateral size of the defect using image processing technology and extracting the width information; the wind speed uses a wind speed sensor to monitor the wind speed in the spraying environment in real time, and transmits the data to the control system for acquisition; the wind speed threshold is set specifically as follows: based on historical data and experience in the spraying environment, combined with the physical properties of the coating and construction requirements, a safe wind speed threshold is set, which is usually the upper limit of the wind speed during the spraying process; the protrusion height of convex defects is obtained by measuring the height of the protrusion using a laser rangefinder or three-dimensional scanning technology; the width and length are obtained by analyzing the contour of the defect using image processing technology and extracting the lateral and longitudinal sizes of the protrusion.

[0038] Through automation and repair, the surface coating of the polyurea assembly tank is ensured to be uniform and smooth, reducing the incidence of defects; the automatic detection and repair system reduces manual intervention, improves production efficiency, and reduces the rework cost caused by defects; through wind speed monitoring and alarm mechanism, spraying is ensured under suitable environmental conditions, reducing construction risks; accurate marking of defect locations ensures that the repair work is more accurate and improves the repair effect.

[0039] See also Figure 2A fully automatic polyurea assembled tank production method, using the above-mentioned fully automatic polyurea assembled tank production system, includes the following steps: obtaining relevant data of the polyurea assembled tank before spraying, the relevant data of the polyurea assembled tank before spraying specifically includes spraying equipment data, spraying environment data, polyurea assembled tank base data and raw material data; detecting through the relevant data of the polyurea assembled tank before spraying to identify whether the polyurea coating spraying is triggered; controlling the polyurea coating spraying based on the spraying parameters, and performing real-time monitoring during the polyurea coating spraying process; performing defect detection after the polyurea coating is sprayed, identifying and marking the defect location; automatically repairing the defect location according to the defect detection result, the automatic repair includes touch-up repair and wear repair; automatically confirming the completion of the production process after the spraying and repair are completed, and outputting a production report.

[0040] In summary, this application has at least the following effects:

[0041] Through the fully automated system, human intervention is reduced, the speed of spraying and defect repair is increased, and the production cycle is shortened; real-time monitoring and defect detection can detect problems in time, ensure product quality, and improve the consistency and reliability of the coating; by accurately controlling spraying parameters and automatic repair mechanisms, paint waste is minimized and material costs are reduced; using data from equipment, environment, substrate and raw materials to make decisions, the level of intelligence in the production process is enhanced, which is helpful for subsequent maintenance and optimization; the automated spraying and repair process ensures that each product has the same coating thickness and color, improving product consistency; automation reduces the impact of human factors on the production process and reduces the probability of operational errors; automatically generates production reports to record the parameters and results of each step for easy traceability and quality audits; the automated system reduces the risks of manual operation in the spraying and repair process and improves operational safety.

[0042] It should be understood by those skilled in the art that the embodiments of the present invention may be provided as methods and systems. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program codes.

[0043] The present invention is described with reference to the flowcharts and structure diagrams of the methods and systems according to the embodiments of the present invention. It should be understood that each process and combination of modules in the flowcharts and structure diagrams can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowcharts. Figure 1process or multiple processes and structures Figure 1 A device that specifies functionality in a module or modules.

[0044] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 process or multiple processes and structures Figure 1 A function specified in a module or multiple modules.

[0045] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 process or multiple processes and structures Figure 1 Steps to specify functionality in a module or multiple modules.

[0046] Although the preferred embodiments of the present invention have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0047] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. A fully automatic polyurea assembly tank production system, characterized in that: include: A data acquisition module is used to acquire relevant data of the polyurea assembled tank before spraying, wherein the relevant data of the polyurea assembled tank before spraying specifically includes spraying equipment data, spraying environment data, polyurea assembled tank base data and raw material data; The spray preparation module is used to detect the relevant data of the polyurea assembly tank before spraying and identify whether to trigger the spraying of polyurea coating; A spraying monitoring module is used to control the spraying of polyurea coating based on spraying parameters and to perform real-time monitoring during the spraying process of polyurea coating; Spraying effect detection and defect recognition module, used to detect defects after the polyurea coating is sprayed, identify and mark the defect locations; A defect repair module is used to automatically repair the defect position according to the defect detection result, and the automatic repair includes repainting repair and wear-off repair; The production completion module is used to automatically confirm the completion of the production process and output the production report after the spraying and repair are completed.

2. The fully automatic polyurea assembly tank production system according to claim 1, characterized in that: The spraying equipment data specifically includes the movement speed of the spray gun and the vibration level of the equipment operation; The spraying environment data specifically includes construction temperature and construction humidity; The polyurea assembled tank substrate data specifically include substrate surface roughness and substrate surface cleanliness; The raw material data specifically include the raw material mixing ratio and the raw material flow rate.

3. The fully automatic polyurea assembly tank production system according to claim 2, characterized in that: The specific analysis of the testing of relevant data before the polyurea assembly tank is as follows: Obtaining preset parameters before spraying of the polyurea assembled tank, wherein the preset parameters before spraying of the polyurea assembled tank specifically include a preset range of spray gun movement speed, a preset range of equipment vibration level, a preset range of construction temperature, a preset range of construction humidity, a preset range of substrate surface roughness, a preset range of substrate surface cleanliness, a preset mixing ratio of raw materials, and a preset range of raw material flow speed; Compare the spray gun moving speed and the equipment operation vibration level with the preset range of the spray gun moving speed and the preset range of the equipment vibration level respectively. When the spray pressure is within the preset range of the spray pressure, the spray gun moving speed is within the preset range of the spray gun moving speed, and the equipment operation vibration level is within the preset range of the equipment vibration level, the spray equipment is marked as qualified; Compare the construction temperature and construction humidity with the preset range of construction temperature and the preset range of construction humidity respectively. When the construction temperature is within the preset range of construction temperature and the construction humidity is within the preset range of construction humidity, it is marked that the spraying environment test is qualified; The surface roughness and cleanliness of the substrate are compared with the preset range of the substrate surface roughness and the preset range of the substrate surface cleanliness respectively. When the surface roughness of the substrate is within the preset range of the substrate surface roughness and the surface cleanliness of the substrate is within the preset range of the substrate surface cleanliness, the polyurea assembly tank substrate is marked as qualified; The raw material mixing ratio and the raw material flow rate are compared with the preset raw material mixing ratio and the preset raw material flow rate range respectively. When the raw material mixing ratio meets the preset raw material mixing ratio and the raw material flow rate is within the preset raw material flow rate range, the raw material inspection is marked as qualified.

4. The fully automatic polyurea assembly tank production system according to claim 3 is characterized in that: The specific identification method of whether to trigger the polyurea paint spraying is: identifying the spraying equipment, spraying environment, polyurea assembly tank base and raw material inspection status. When the spraying equipment inspection is qualified, the spraying environment inspection is qualified, the polyurea assembly tank base inspection is qualified, and the raw material inspection is qualified, the polyurea paint spraying is triggered.

5. The fully automatic polyurea assembly tank production system according to claim 1, characterized in that: The control of the polyurea coating spraying based on the spraying parameters specifically comprises: obtaining the spraying parameters, and controlling and adjusting in real time based on the spraying parameters during the polyurea coating spraying process, wherein the spraying parameters specifically include the spraying distance, the spraying angle and the spraying pressure; The real-time control and adjustment specifically includes: obtaining the actual spraying distance, actual spraying angle and actual spraying pressure in real time, and when the actual spraying distance, actual spraying angle and actual spraying pressure deviate from the spraying distance, spraying angle and spraying pressure in the spraying parameters, adjusting the deviation data in real time.

6. The fully automatic polyurea assembly tank production system according to claim 1, characterized in that: After the polyurea coating is sprayed, the specific analysis of defect detection, identification and marking of defect locations is as follows: Acquire a surface image of the polyurea assembled tank based on a defect detection device, and preprocess the surface image of the polyurea assembled tank, wherein the preprocessing includes removing background noise, image grayscale processing, and image segmentation; The edge detection algorithm is used to identify the edge of the coating surface, and the texture analysis method is used to detect the uniformity and smoothness of the coating. Then, the defects and positions in the surface image of the polyurea assembly tank are identified based on the defect model. The identified defects are classified and the surface position coordinates of each defect on the polyurea assembly tank are marked. The specific classifications include pinhole defects, concave defects and convex defects.

7. The fully automatic polyurea assembly tank production system according to claim 6, characterized in that: The specific analysis of automatically repairing the defect position according to the defect detection result is as follows: For the pinhole defect and the concave defect, repainting and repairing are performed, and the specific steps of the repainting and repairing are: obtaining the defect depth and defect width of the pinhole defect and the concave defect, identifying the wind speed during the repainting and repairing, comparing the wind speed with the spraying wind speed threshold, and when the wind speed is less than or equal to the wind speed threshold, obtaining the amount of repainted polyurea coating based on the defect depth and defect width, and then repainting and repairing based on the amount of repainted polyurea coating and the surface position coordinates of the pinhole defect or the concave defect on the polyurea assembled tank; When the wind speed is greater than the wind speed threshold, an alarm mechanism is used to prompt construction workers to perform manual windbreak spraying; For the convex defect, grinding and repair are performed, and the specific steps of the grinding and repair are: obtaining the convex height, convex width and convex length of the convex defect, marking the convex boundary according to the convex height, convex width and convex length of the convex defect, and automatically grinding the convex defect until the grinding touches the convex boundary, then stopping the grinding.

8. A method for producing a fully automatic polyurea assembly tank, using a fully automatic polyurea assembly tank production system according to any one of claims 1 to 7, characterized in that: The following steps are involved: Acquire relevant data before the polyurea assembled tank is sprayed, wherein the relevant data before the polyurea assembled tank is sprayed specifically includes spraying equipment data, spraying environment data, polyurea assembled tank base data and raw material data; Through the relevant data of the polyurea assembly tank before spraying, it is detected whether the polyurea coating spraying is triggered; Control the polyurea coating spraying based on the spraying parameters and conduct real-time monitoring during the polyurea coating spraying process; Conduct defect detection on polyurea coating after spraying, identify and mark defect locations; Automatically repairing the defective position according to the defect detection result, wherein the automatic repair includes repainting repair and wear-off repair; After spraying and repairing are completed, the production process is automatically confirmed to be completed and a production report is output.

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