Intelligent spraying control system and method

Abstract

The invention discloses an intelligent spraying control system which comprises a preheating module, an electrostatic painting module, an air energy water lifting module, an infrared quick-drying module, an air energy secondary drying module, a control module and a man-machine interaction module. The invention further discloses an intelligent spraying control method. The intelligent spraying control method comprises the following steps that S1, paint spraying parameters are set through the man-machine interaction module; s2, coordinating the work of each module through a control module; s3, preheating treatment is conducted on the workpiece through a preheating module; s4, after the workpiece is pretreated, the workpiece is subjected to electrostatic spraying through an electrostatic paint spraying module; s5, a clean water source needed by spraying is provided through an air energy water lifting module; s6, infrared heating is conducted through an infrared quick-drying module, and drying of the coating is accelerated; s7, the coating is further dried until drying is completed; and S8, the workpiece is taken down, and spraying is completed. According to the technical scheme, intelligent control over the spraying process can be achieved, the spraying quality, the production efficiency and the environmental protection performance are improved, and important practical application value is achieved.

Description

Technical Field

[0001] The present invention belongs to the field of spraying technology, and in particular relates to an intelligent spraying control system and method. Background Art

[0002] Spraying technology is widely used in the fields of automobile manufacturing, furniture manufacturing, and home appliance production to improve the surface quality and aesthetics of products. Spraying is a coating method that uses a spray gun or a disc atomizer to disperse the spray into uniform and fine droplets by pressure or centrifugal force and apply them to the surface of the object.

[0003] The existing spray control system and method mainly rely on manual operation, and have the following problems: the existing spray control system has a low degree of automation and requires a lot of manual intervention. It is difficult to ensure the uniformity of the coating through a large amount of manual intervention in spraying, resulting in unstable product quality. The traditional spraying process is time-consuming and has low production efficiency. The volatile organic compounds (VOCs) generated during the spraying process are harmful to the environment and human health. For this reason, we propose an intelligent spray control system and method. Summary of the invention

[0004] The purpose of the present invention is to provide an intelligent spraying control system and method to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions: an intelligent spray control system, comprising a preheating module, an electrostatic spray paint module, an air energy water extraction module, an infrared quick drying module, an air energy secondary drying module, a control module and a human-computer interaction module; The preheating module includes a heating element and a temperature control system, which are used to preheat the workpiece to improve the adhesion of the coating. The preheating module includes a heating element and a first temperature control system. The heating element uses an electric heating wire to throw the workpiece for preheating. The first temperature control system uses a temperature sensor to monitor and control the preheating temperature in real time. The electrostatic spray paint module is used to electrostatically spray the workpiece. The electrostatic spray paint module includes a spray gun, a high-voltage power supply and a controller. The spray gun adopts an electrostatic spray gun, which generates an electrostatic field to charge the paint. The high-voltage power supply is used to provide a high voltage to charge the paint and adsorb it on the surface of the workpiece. The controller includes a spray gun control unit and a spray paint parameter setting unit, which are used to control the spray paint process. The air-to-water extraction module is used to provide a clean water source required for spraying. The air-to-water extraction module includes an air-to-heat pump and a water treatment system. The air-to-heat pump uses the heat in the air to extract moisture to provide a clean water source. The water treatment system filters the clean water source through a first filter to ensure the cleanliness of the water source. The infrared quick-drying module is used to accelerate the drying process of the coating and shorten the production cycle. The infrared quick-drying module includes infrared heating lamps and a second temperature control system. The infrared heating lamps are evenly distributed in the drying chamber for infrared heating. The temperature control system includes a temperature sensor and a controller for real-time monitoring and control of the drying temperature. The air energy secondary drying module adopts an air energy heat pump, which uses the heat in the air to provide the heat required for drying, and further dries the coating; The control module is used to control the system and coordinate the work of each module to perform intelligent control; The human-computer interaction module is used to display system status and operation instructions and provide user interaction functions.

[0006] Preferably, the intelligent spray control system also includes an environmental monitoring module, an exhaust gas treatment module and a data recording and analysis module. The environmental monitoring module is used to monitor the humidity and VOCs concentration in the spray environment. The exhaust gas treatment module is used to treat the exhaust gas generated during the spraying process to reduce environmental pollution. The data recording and analysis module is used to record the data during the spraying process and perform analysis and optimization.

[0007] Preferably, the environmental monitoring device includes a humidity sensor and a VOCs sensor, the humidity sensor is used to monitor the environmental humidity, and the VOCs sensor is used to monitor the VOCs concentration generated during the spraying process; the exhaust gas treatment module includes an exhaust gas collection unit, a second filter and a purification unit, the exhaust gas collection unit is used to collect the exhaust gas generated during the spraying process, and the second filter is used to preliminarily filter the particulate matter in the exhaust gas. The purification unit uses activated carbon adsorption and catalytic combustion technology to further purify the exhaust gas.

[0008] Preferably, the preheating temperature in the preheating module is controlled by a temperature control formula, and the temperature control formula is specifically as follows: ; Among them, T out is the output control signal; K p is the proportional gain; K i is the integral gain; K d is the differential gain; T set is the set temperature; T current is the current temperature.

[0009] Preferably, the infrared quick-drying module and the air energy secondary drying module both calculate the drying rate by a drying rate formula, and the drying rate is controlled by adjusting the temperature of the infrared heating lamp. The drying rate formula is specifically as follows: ; Where R is the drying rate; k is the drying coefficient; T is the temperature of the drying chamber; T ambient is the ambient temperature.

[0010] The intelligent spraying control method comprises the following steps: S1. Set the painting parameters through the human-computer interaction module and start the preheating, electrostatic painting, infrared quick drying and air energy secondary drying processes; S2. Coordinate the work of each module through the control module, perform intelligent control, monitor the working status of each device in real time during the production process, and make adjustments and maintenance when necessary; S3. Preheating the workpiece through a preheating module; S4. After the workpiece is pretreated, the workpiece is electrostatically sprayed by an electrostatic spraying module; S5. Provide the clean water source required for spraying through the air-to-water module; S6. Infrared heating is performed through the infrared quick-drying module to accelerate the drying of the paint; S7. The air energy secondary drying module adopts an air energy heat pump to use the heat in the air to provide the heat required for drying, and further dry the coating until the drying is completed; S8. Remove the workpiece and complete the spraying.

[0011] Preferably, the following steps are also included: S9. Monitor the humidity and VOCs concentration in the spraying environment, treat the waste gas generated during the spraying process, reduce environmental pollution, record the data during the spraying process, and perform analysis and optimization.

[0012] Preferably, the specific steps of S9 include: monitoring the ambient humidity through a humidity sensor, and monitoring the VOCs concentration generated during the spraying process through a VOCs sensor; collecting the exhaust gas generated during the spraying process through a waste gas collection unit, preliminarily filtering the collected exhaust gas through a second filter, and then using activated carbon adsorption and catalytic combustion technology to further purify the exhaust gas; using a data acquisition card to collect data from each sensor, and storing the collected data for analyzing the data and providing optimization suggestions.

[0013] Preferably, in the process of purifying the exhaust gas in S9, a VOCs removal rate formula is used to calculate the VOCs removal rate in the treatment to evaluate the treatment effect. The VOCs removal rate formula is specifically as follows: %; Where, E is the VOCs removal rate; C out is the VOCs concentration after treatment; C in is the VOCs concentration before treatment.

[0014] Preferably, when analyzing the data in S9, a data analysis formula is used to calculate the average value of the data recorded in the system to help analyze the performance during the spraying process, and a standard deviation formula is used to calculate the standard deviation of the data recorded in the system to help evaluate the degree of dispersion of the data. The data analysis formula is specifically as follows: ; The standard deviation formula is as follows: ; Where Mean is the average value; n is the number of data points; x i is the value of the ith data point; σ is the standard deviation.

[0015] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention realizes uniformity and high efficiency of spraying through an electrostatic spray paint module, thereby improving product quality. At the same time, before spraying, a preheating module is provided to preheat the workpiece to improve the adhesion of the paint, thereby further improving the quality of the nozzle; the air-energy water extraction module provides a clean water source to reduce the impact on the environment and reduce pollution. At the same time, the infrared quick-drying module and the air-energy secondary drying module can accelerate the drying process of the paint, shorten the production cycle, and increase work efficiency. The system can perform intelligent control, reduce manual intervention, and facilitate users to set up and manage the system, thereby further improving production efficiency; (2) The present invention can monitor the safety of the spraying environment and treat the waste gas generated during the engineering process through the environmental monitoring module and the waste gas treatment module, thereby reducing environmental pollution and being green and environmentally friendly. The data during the spraying process can be recorded, analyzed and optimized through the data recording and analysis module, which is conducive to improving production efficiency and product quality; (3) The method of the present invention realizes intelligent control of the spraying process through key technologies such as preheating, electrostatic spraying, air-energy water extraction, infrared quick drying, air-energy secondary drying, environmental monitoring, waste gas treatment, and data recording and analysis, thereby improving the spraying quality, production efficiency, and environmental protection performance, and has important practical application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a structural block diagram of the present invention.

[0017] Figure 2 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] For example, see Figure 1 , the present invention provides a technical solution: an intelligent spray control system, including a preheating module, an electrostatic spray paint module, an air energy water extraction module, an infrared quick drying module, an air energy secondary drying module, a control module and a human-computer interaction module; The preheating module includes a heating element and a temperature control system, which are used to preheat the workpiece to improve the adhesion of the coating. The preheating module includes a heating element and a first temperature control system. The heating element uses an electric heating wire to throw the workpiece for preheating. The first temperature control system uses a temperature sensor to monitor and control the preheating temperature in real time. The electrostatic spray paint module is used to electrostatically spray the workpiece. The electrostatic spray paint module includes a spray gun, a high-voltage power supply and a controller. The spray gun adopts an electrostatic spray gun, which generates an electrostatic field to charge the paint. The high-voltage power supply is used to provide a high voltage to charge the paint and adsorb it on the surface of the workpiece. The controller includes a spray gun control unit and a spray paint parameter setting unit, which are used to control the spray paint process. The air-to-water extraction module is used to provide a clean water source required for spraying. The air-to-water extraction module includes an air-to-heat pump and a water treatment system. The air-to-heat pump uses the heat in the air to extract moisture to provide a clean water source. The water treatment system filters the clean water source through a first filter to ensure the cleanliness of the water source. The infrared quick-drying module is used to accelerate the drying process of the coating and shorten the production cycle. The infrared quick-drying module includes infrared heating lamps and a second temperature control system. The infrared heating lamps are evenly distributed in the drying chamber for infrared heating. The temperature control system includes a temperature sensor and a controller for real-time monitoring and control of the drying temperature. The air energy secondary drying module adopts an air energy heat pump, which uses the heat in the air to provide the heat required for drying, and further dries the coating; The control module is used to control the system and coordinate the work of each module to perform intelligent control; The human-computer interaction module is used to display system status and operation instructions and provide user interaction functions.

[0020] The preheating module controls the preheating temperature by using a temperature control formula to control the temperature. The temperature control formula is as follows: ; Among them, T out is the output control signal; K p is the proportional gain; K i is the integral gain; K d is the differential gain; T set is the set temperature; T current is the current temperature.

[0021] The infrared quick drying module and the air energy secondary drying module both calculate the drying rate through the drying rate formula, and control the drying rate by adjusting the temperature of the infrared heating lamp. The drying rate formula is as follows: ; Where R is the drying rate; k is the drying coefficient; T is the temperature of the drying chamber; T ambient is the ambient temperature.

[0022] In this technical solution, the electrostatic paint spraying module is used to achieve uniformity and efficiency in spraying, thereby improving product quality. At the same time, before spraying, the workpiece is preheated by the set preheating module to improve the adhesion of the paint, thereby further improving the quality of the nozzle. The air-energy water extraction module is used to provide a clean water source to reduce the impact on the environment and reduce pollution. At the same time, the infrared quick-drying module and the air-energy secondary drying module can accelerate the drying process of the paint, shorten the production cycle, and increase work efficiency. The system can perform intelligent control, reduce manual intervention, and facilitate users to set up and manage the system, thereby further improving production efficiency.

[0023] Example 2 is improved on the basis of Example 1, please refer to Figure 1 Specifically: the intelligent spray control system also includes an environmental monitoring module, an exhaust gas treatment module and a data recording and analysis module. The environmental monitoring module is used to monitor the humidity and VOCs concentration in the spray environment. The exhaust gas treatment module is used to treat the exhaust gas generated during the spraying process to reduce environmental pollution. The data recording and analysis module is used to record the data during the spraying process and perform analysis and optimization.

[0024] In this embodiment, preferably, the environmental monitoring device includes a humidity sensor and a VOCs sensor, the humidity sensor is used to monitor the environmental humidity, and the VOCs sensor is used to monitor the VOCs concentration generated during the spraying process; the exhaust gas treatment module includes an exhaust gas collection unit, a second filter and a purification unit, the exhaust gas collection unit is used to collect the exhaust gas generated during the spraying process, and the second filter is used to preliminarily filter the particulate matter in the exhaust gas. The purification unit uses activated carbon adsorption and catalytic combustion technology to further purify the exhaust gas.

[0025] In this technical solution, through the environmental monitoring module and the waste gas treatment module, the safety of the spraying environment can be monitored, and the waste gas generated during the engineering process can be treated, thereby reducing environmental pollution and being green and environmentally friendly. Through the data recording and analysis module, the data of the spraying process can be recorded, analyzed and optimized, which is conducive to improving production efficiency and product quality.

[0026] The difference between the third embodiment and the second embodiment is that, please refer to Figure 2 , specifically: an intelligent spraying control method, comprising the following steps: S1. Set the painting parameters through the human-computer interaction module and start the preheating, electrostatic painting, infrared quick drying and air energy secondary drying processes; S2. Coordinate the work of each module through the control module, perform intelligent control, monitor the working status of each device in real time during the production process, and make adjustments and maintenance when necessary; S3. Preheating the workpiece through a preheating module; S4. After the workpiece is pretreated, the workpiece is electrostatically sprayed by an electrostatic spraying module; S5. Provide the clean water source required for spraying through the air-to-water module; S6. Infrared heating is performed through the infrared quick-drying module to accelerate the drying of the paint; S7. The air energy secondary drying module adopts an air energy heat pump to use the heat in the air to provide the heat required for drying, and further dry the coating until the drying is completed; S8. Remove the workpiece and complete the spraying.

[0027] In this embodiment, preferably, the following steps are also included: S9. Monitor the humidity and VOCs concentration in the spraying environment, treat the waste gas generated during the spraying process, reduce environmental pollution, record the data during the spraying process, and perform analysis and optimization.

[0028] In this embodiment, preferably, the specific steps of S9 include: monitoring the ambient humidity through a humidity sensor, and monitoring the VOCs concentration generated during the spraying process through a VOCs sensor; collecting the exhaust gas generated during the spraying process through a waste gas collection unit, preliminarily filtering the collected exhaust gas through a second filter, and then using activated carbon adsorption and catalytic combustion technology to further purify the exhaust gas; using a data acquisition card to collect data from each sensor, and storing the collected data for analyzing the data and providing optimization suggestions.

[0029] In this embodiment, preferably, in the process of purifying the exhaust gas in S9, a VOCs removal rate formula is used to calculate the VOCs removal rate in the treatment to evaluate the treatment effect. The VOCs removal rate formula is specifically as follows: %; Where, E is the VOCs removal rate; C out is the VOCs concentration after treatment; C in is the VOCs concentration before treatment.

[0030] In this embodiment, preferably, when analyzing data in S9, a data analysis formula is used to calculate the average value of the data recorded in the system to help analyze the performance during the spraying process, and a standard deviation formula is used to calculate the standard deviation of the data recorded in the system to help evaluate the degree of dispersion of the data. The data analysis formula is specifically as follows: ; The standard deviation formula is as follows: ; Where Mean is the average value; n is the number of data points; x i is the value of the ith data point; σ is the standard deviation.

[0031] In this technical solution, through key technologies such as preheating, electrostatic spraying, air-energy water extraction, infrared quick drying, air-energy secondary drying, environmental monitoring, exhaust gas treatment, and data recording and analysis, intelligent control of the spraying process is realized, the spraying quality, production efficiency and environmental protection performance are improved, and it has important practical application value.

[0032] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. Intelligent spraying control system, characterized by: It includes preheating module, electrostatic painting module, air-energy water extraction module, infrared quick-drying module, air-energy secondary drying module, control module and human-computer interaction module; The preheating module includes a heating element and a temperature control system, which are used to preheat the workpiece to improve the adhesion of the coating. The preheating module includes a heating element and a first temperature control system. The heating element uses an electric heating wire to throw the workpiece for preheating. The first temperature control system uses a temperature sensor to monitor and control the preheating temperature in real time. The electrostatic spray paint module is used to electrostatically spray the workpiece. The electrostatic spray paint module includes a spray gun, a high-voltage power supply and a controller. The spray gun adopts an electrostatic spray gun, which generates an electrostatic field to charge the paint. The high-voltage power supply is used to provide a high voltage to charge the paint and adsorb it on the surface of the workpiece. The controller includes a spray gun control unit and a spray paint parameter setting unit, which are used to control the spray paint process. The air-to-water extraction module is used to provide a clean water source required for spraying. The air-to-water extraction module includes an air-to-heat pump and a water treatment system. The air-to-heat pump uses the heat in the air to extract moisture to provide a clean water source. The water treatment system filters the clean water source through a first filter to ensure the cleanliness of the water source. The infrared quick-drying module is used to accelerate the drying process of the coating and shorten the production cycle. The infrared quick-drying module includes infrared heating lamps and a second temperature control system. The infrared heating lamps are evenly distributed in the drying chamber for infrared heating. The temperature control system includes a temperature sensor and a controller for real-time monitoring and control of the drying temperature. The air energy secondary drying module adopts an air energy heat pump, which uses the heat in the air to provide the heat required for drying, and further dries the coating; The control module is used to control the system and coordinate the work of each module to perform intelligent control; The human-computer interaction module is used to display system status and operation instructions and provide user interaction functions.

2. The intelligent spraying control system according to claim 1 is characterized in that: The intelligent spray control system also includes an environmental monitoring module, an exhaust gas treatment module and a data recording and analysis module. The environmental monitoring module is used to monitor the humidity and VOCs concentration in the spray environment. The exhaust gas treatment module is used to treat the exhaust gas generated during the spraying process to reduce environmental pollution. The data recording and analysis module is used to record the data during the spraying process and perform analysis and optimization.

3. The intelligent spraying control system according to claim 2 is characterized in that: The environmental monitoring device includes a humidity sensor and a VOCs sensor. The humidity sensor is used to monitor the environmental humidity, and the VOCs sensor is used to monitor the VOCs concentration generated during the spraying process. The exhaust gas treatment module includes an exhaust gas collection unit, a second filter and a purification unit. The exhaust gas collection unit is used to collect the exhaust gas generated during the spraying process, and the second filter is used to preliminarily filter the particulate matter in the exhaust gas. The purification unit uses activated carbon adsorption and catalytic combustion technology to further purify the exhaust gas.

4. The intelligent spraying control system according to claim 1, characterized in that: The preheating module controls the preheating temperature by using a temperature control formula to control the temperature. The temperature control formula is as follows: ； Among them, T out is the output control signal; K p is the proportional gain; K i is the integral gain; K d is the differential gain; T set is the set temperature; T current is the current temperature.

5. The intelligent spraying control system according to claim 4 is characterized in that: The infrared quick drying module and the air energy secondary drying module both calculate the drying rate through the drying rate formula, and control the drying rate by adjusting the temperature of the infrared heating lamp. The drying rate formula is as follows: ； Where R is the drying rate; k is the drying coefficient; T is the temperature of the drying chamber; T ambient is the ambient temperature.

6. Intelligent spraying control method, according to the intelligent spraying control system according to any one of claims 1-5, characterized in that: The following steps are involved: S1. Set the painting parameters through the human-computer interaction module and start the preheating, electrostatic painting, infrared quick drying and air energy secondary drying processes; S2. Coordinate the work of each module through the control module, perform intelligent control, monitor the working status of each device in real time during the production process, and make adjustments and maintenance when necessary; S3. Preheating the workpiece through a preheating module; S4. After the workpiece is pretreated, the workpiece is electrostatically sprayed by an electrostatic spraying module; S5. Provide the clean water source required for spraying through the air-to-water module; S6. Infrared heating is performed through the infrared quick-drying module to accelerate the drying of the paint; S7. The air energy secondary drying module adopts an air energy heat pump to use the heat in the air to provide the heat required for drying, and further dry the coating until the drying is completed; S8. Remove the workpiece and complete the spraying.

7. The intelligent spraying control method according to claim 6, characterized in that: The following steps are also included: S9. Monitor the humidity and VOCs concentration in the spraying environment, treat the waste gas generated during the spraying process, reduce environmental pollution, record the data during the spraying process, and analyze and optimize it.

8. The intelligent spraying control method according to claim 7, characterized in that: The specific steps of S9 include: monitoring the ambient humidity through a humidity sensor, and monitoring the VOCs concentration generated during the spraying process through a VOCs sensor; collecting the exhaust gas generated during the spraying process through an exhaust gas collection unit, preliminarily filtering the collected exhaust gas through a second filter, and then using activated carbon adsorption and catalytic combustion technology to further purify the exhaust gas; using a data acquisition card to collect data from each sensor, and storing the collected data for analyzing the data and providing optimization suggestions.

9. The intelligent spraying control method according to claim 8, characterized in that: In the process of purifying the exhaust gas in S9, the VOCs removal rate formula is used to calculate the VOCs removal rate in the treatment to evaluate the treatment effect. The VOCs removal rate formula is as follows: %； Where, E is the VOCs removal rate; C out is the VOCs concentration after treatment; C in is the VOCs concentration before treatment.

10. The intelligent spraying control method according to claim 9, characterized in that: When analyzing data in S9, a data analysis formula is used to calculate the average value of the data recorded in the system to help analyze the performance during the spraying process, and a standard deviation formula is used to calculate the standard deviation of the data recorded in the system to help evaluate the degree of dispersion of the data. The data analysis formula is specifically as follows: ； The standard deviation formula is as follows: ； Where Mean is the average value; n is the number of data points; x i is the value of the ith data point; σ is the standard deviation.

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