Spraying robot anti-blocking detecting and cleaning system and method

Abstract

The invention discloses an anti-blocking detecting and cleaning system and method for a spraying robot, and is applied to the technical field of robots. The system comprises an industrial personal computer (1), a communication module (2), a spray gun (3), a spraying machine pump (4), a storage box (5), a clear water tank (6), a pressure sensor (7), a first flow sensor (8), a second flow sensor (9) and a third flow sensor (10). After cleaning of the spraying robot is completed, the detector is used for detecting and feeding back the spraying robot pipeline, and the spraying quality and efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the field of robot technology, and more particularly to a spray robot anti-blocking detection and cleaning system and method. Background Art

[0002] With the development of the construction industry, spray robots are being used more and more widely. Most robots do not have anti-blocking detection devices. When the spray pipeline is blocked, it is impossible to provide timely feedback to the spray robot controller, and the reliability and safety of the spray robot cannot be determined, resulting in waste of paint. After the spray robot is cleaned, most robots cannot perform detection and feedback on the cleaning of the spray robot.

[0003] Disadvantages of spray robot cleaning may include:

[0004] Incomplete cleaning: Due to the complex structure of the spray robot, cleaning may not reach every corner, resulting in some dirt remaining on the surface or inside the robot; Difficult to clean: Spray robots usually have many moving parts and connecting parts, which are difficult to clean and require a long time and effort; High cleaning costs: Due to the complexity of the spray robot, the cost of equipment and materials required for cleaning is high, which imposes a certain economic burden on the company; Insufficient cleaning frequency: Since cleaning work is tedious and time-consuming, the cleaning frequency may be insufficient, which in turn affects the normal operation and service life of the robot; Cumbersome cleaning process: Cleaning the spray robot requires disassembly and reassembly steps, which is cumbersome and prone to errors or omissions, affecting the cleaning effect.

[0005] Therefore, it is an urgent problem for technical personnel in this field to propose a spray robot anti-blocking detection and cleaning system and method to solve the difficulties existing in the prior art. Summary of the invention

[0006] In view of this, the present invention provides a spray robot anti-blocking detection and cleaning system and method to solve the problems of low cleaning efficiency, inability to provide detection feedback on cleaning, and low spraying quality and efficiency.

[0007] In order to achieve the above object, the present invention provides the following technical solutions:

[0008] A spray robot anti-blocking detection and cleaning system, comprising: an industrial computer, a communication module, a spray gun, a spray machine pump, a material storage box, a clean water tank, a pressure sensor, a first flow sensor, a second flow sensor and a third flow sensor;

[0009] The pressure sensor is arranged on the spray gun;

[0010] The spray gun is connected to the spray machine pump through a first pipeline, and a third flow sensor is arranged on the first pipeline;

[0011] The material storage tank and the clean water tank are connected to the sprayer pump through the second pipeline and the third pipeline respectively;

[0012] The first flow sensor is arranged in the second pipeline, and the second flow sensor is arranged in the third pipeline;

[0013] The spray gun and the spray machine pump are respectively connected to the first output port of the communication module;

[0014] The pressure sensor, the first flow sensor, the second flow sensor and the third flow sensor are respectively connected to the second output port of the communication module;

[0015] The industrial computer is communicatively connected with the communication module.

[0016] In the above system, optionally, the spray gun is provided with a spray gun port, and the pressure sensor is provided at the connection between the spray gun port and the first pipeline.

[0017] In the above system, optionally, a three-way valve is provided between the sprayer pump, the material storage tank and the clean water tank.

[0018] In the above system, optionally, the three-way valve includes a paint valve, a clean water valve and a main valve.

[0019] In the above system, optionally, the paint valve is connected to the second pipeline, the clean water valve is connected to the third pipeline, and the main valve is connected to the fourth pipeline connected to the sprayer pump.

[0020] A spray robot anti-blocking detection and cleaning method, based on any one of the above-mentioned spray robot anti-blocking detection and cleaning systems, comprises an anti-blocking detection step and a cleaning step.

[0021] The above method may optionally include the following anti-blocking detection steps:

[0022] S1-1. During the spraying process, the pressure sensor collects the pressure data of the spray gun in real time, the first flow sensor collects the first flow data of the second pipeline between the storage box and the spray pump in real time, and the third flow sensor collects the second flow data of the first pipeline between the spray pump and the spray gun in real time; the pressure data, the first flow data and the second flow data are sent to the industrial computer through the communication module;

[0023] S1-2. The industrial computer compares the pressure data with the preset pressure range. If the pressure data deviates from the normal range, the industrial computer triggers an alarm or automatically controls the spray gun and the spray machine pump to stop working;

[0024] S1-3. The industrial computer analyzes the pressure data, the first flow data and the second flow data, determines that the fault is a blockage or a leak, and further locates the fault and performs troubleshooting.

[0025] The above method, optional, cleaning step:

[0026] S2-1. Setting of cleaning program: According to different spraying construction process requirements, the parameters of the cleaning program, including cleaning time and cleaning pressure, are set through the industrial computer;

[0027] S2-2. Cleaning program triggering: The industrial computer sends the corresponding cleaning parameters to the spray gun and spray machine pump through the communication module;

[0028] S2-3. Execution of the cleaning action: The water in the storage tank or the clean water tank is used to clean the pipes and the spray gun through the spray machine pump;

[0029] S2-4. Feedback of cleaning action: After the cleaning procedure is completed, the industrial computer obtains the real-time detection values ​​of the pressure sensor, the first flow sensor, the second flow sensor and the third flow sensor and analyzes and judges them to obtain the cleaning results, including cleaning success, cleaning failure and cleaning abnormality.

[0030] It can be seen from the above technical solutions that, compared with the prior art, the present invention discloses a spray robot anti-blocking detection and cleaning system and method, which has the following beneficial effects:

[0031] The present invention has two cleaning modes for the spray robot, namely, material storage box cleaning and clean water tank cleaning, which can clean the pipeline and the spray machine to avoid damage to the equipment caused by material solidification, thereby extending the service life; after the cleaning of the spray robot is completed, a detector is used to detect and feedback the pipeline of the spray robot to improve the quality and efficiency of spraying. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0033] Figure 1 This is a structural block diagram of a spray robot anti-blocking detection and cleaning system disclosed in the present invention;

[0034] Figure 2 This is a specific structural diagram of the three-way valve disclosed in the present invention;

[0035] Figure 3 It is a schematic diagram of the structure of a spray gun provided with a pressure sensor disclosed in the present invention;

[0036] Figure 4 for Figure 3 a side perspective view of the spray gun shown;

[0037] Figure 5 for Figure 3 a corresponding side perspective view of the spray gun shown;

[0038] Among them, 1 is an industrial computer, 2 is a communication module, 3 is a spray gun, 3-1 is a spray gun nozzle, 4 is a spray machine pump, 5 is a storage box, 6 is a clean water tank, 7 is a pressure sensor, 8 is a first flow sensor, 9 is a second flow sensor, 10 is a third flow sensor, 11 is a three-way valve, 11-1 is a paint valve, 11-2 is a clean water valve, and 11-3 is a main valve. DETAILED DESCRIPTION

[0039] 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.

[0040] Reference Figure 1 As shown, the present invention discloses a spray robot anti-blocking detection and cleaning system, including: an industrial computer 1, a communication module 2, a spray gun 3, a spray machine pump 4, a material storage box 5, a clean water tank 6, a pressure sensor 7, a first flow sensor 8, a second flow sensor 9 and a third flow sensor 10;

[0041] See also Figure 3 As shown, the pressure sensor 7 is arranged on the spray gun 3;

[0042] The spray gun 3 is connected to the spray pump 4 through a first pipeline, and a third flow sensor 10 is arranged on the first pipeline;

[0043] The material storage tank 5 and the clean water tank 6 are connected to the sprayer pump through the second pipeline and the third pipeline respectively;

[0044] The first flow sensor 8 is arranged in the second pipeline, and the second flow sensor 9 is arranged in the third pipeline;

[0045] The spray gun 3 and the spray pump 4 are respectively connected to the first output port of the communication module 2;

[0046] The pressure sensor 7, the first flow sensor 8, the second flow sensor 9 and the third flow sensor 10 are respectively connected to the second output port of the communication module 2;

[0047] The industrial computer 1 is communicatively connected with the communication module 2 .

[0048] For further information, see Figure 3-Figure 5 As shown, the spray gun 3 is provided with a spray gun port 3-1, and the pressure sensor 7 is arranged at the connection between the spray gun port 3-1 and the first pipeline.

[0049] Specifically, the pressure sensor 7 is installed on the top of the spray gun 3, and the connecting part of the pressure sensor 7 is connected to the outlet part of the spray gun 3 to ensure a tight connection. The pressure sensor 7 is fixed to the outlet of the spray gun 3 with screws to ensure that the pressure sensor 7 is firmly installed on the spray gun 3. A connecting cable is connected to the output port of the pressure sensor 7 to connect the pressure sensor 7 to the monitoring device or the industrial computer 1.

[0050] Abnormal pressure changes may be a sign of pipeline blockage. If the pressure is abnormal, it may be caused by pipeline blockage, gear pump wear, etc. The pressure range of the spray robot during normal operation is 12-16mpa.

[0051] It is necessary to monitor the feedback data of the pressure sensor 7 in real time, analyze the data of the pressure sensor, and look for abnormal signals. For example, if the pressure in a certain area drops suddenly, it may indicate that there is a leak in that area. Similarly, if the flow rate displayed by the flow sensor is lower than expected, it may be due to a blockage in a certain section of the pipeline.

[0052] For further information, see Figure 2 As shown, a three-way valve 11 is arranged between the sprayer pump 4 , the material storage box 5 and the clean water tank 6 .

[0053] Furthermore, the three-way valve 11 includes a paint valve 11 - 1 , a clean water valve 11 - 2 and a main valve 11 - 3 .

[0054] Paint valve 11-1: mainly responsible for controlling the flow of paint, and realizing the opening or closing of paint by controlling the valve switch. When paint 11-1 is opened, the paint is transported from the storage box 5 to the spray gun 3 for spraying operation.

[0055] Clean water valve 11-2: used to control the flow of cleaning water. After spraying, clean water is needed to clean the spray gun, pipes and other parts to prevent paint residue from clogging or affecting the subsequent spraying effect. The working principle of the clean water valve is similar to that of the paint valve, and the cleaning water is turned on or off by controlling the switch of the valve.

[0056] Main valve 11-3: It plays the role of regulating the circulation or reflux of paint. It can ensure that the paint maintains a certain pressure and flow in the system, while avoiding paint waste or excessive accumulation. When the spraying operation is suspended or ended, the main valve can help return the excess paint to the storage tank or designated collection container, reducing paint loss and environmental pollution.

[0057] Furthermore, the paint valve 11 - 1 is connected to the second pipeline, the clean water valve 11 - 2 is connected to the third pipeline, and the main valve 11 - 3 is connected to the fourth pipeline connected to the sprayer pump 4 .

[0058] and Figure 1 Corresponding to the system shown, the present invention also discloses a spray robot anti-blocking detection and cleaning method, including an anti-blocking detection step and a cleaning step.

[0059] Furthermore, the anti-blocking detection step includes:

[0060] S1-1. During the spraying process, the pressure sensor 7 collects the pressure data of the spray gun 3 in real time, the first flow sensor 8 collects the first flow data of the second pipeline between the storage box 5 and the spray pump 4 in real time, and the third flow sensor 10 collects the second flow data of the first pipeline between the spray pump 4 and the spray gun 3 in real time; the pressure data, the first flow data and the second flow data are sent to the industrial computer 1 through the communication module 2;

[0061] S1-2. The industrial computer 1 compares the pressure data with the preset pressure range. If the pressure data deviates from the normal range, the industrial computer 1 triggers an alarm or automatically controls the spray gun 3 and the spray pump 4 to stop working;

[0062] S1-3. The industrial computer 1 analyzes the pressure data, the first flow data and the second flow data, determines that the fault is a blockage or a gas leakage, and further locates the fault and performs troubleshooting.

[0063] Specifically, the collected pressure data, first flow data, and second flow data are compared with the normal values ​​set by the system. If there is a significant difference between the current data and the normal values, there may be a blockage or leakage. The trend of data changes is analyzed. For example, a continuous increase in pressure and a decrease in flow may indicate a blockage, while a decrease in pressure and an increase in flow may be a sign of leakage.

[0064] Further, the cleaning step includes:

[0065] S2-1. Setting of cleaning program: According to different spraying construction process requirements, the parameters of the cleaning program are set by the industrial computer 1, including cleaning time and cleaning pressure;

[0066] S2-2. Cleaning program trigger: The industrial computer 1 sends the corresponding cleaning parameters to the spray gun 3 and the spray pump 4 through the communication module 2;

[0067] S2-3. Execution of the cleaning action: The water in the storage tank 5 or the water tank 6 is cleaned by the sprayer pump 4 through the pipes and the spray gun 3;

[0068] S2-4. Feedback of cleaning action: After the cleaning procedure is completed, the industrial computer 1 obtains the real-time detection values ​​of the pressure sensor 7, the first flow sensor 8, the second flow sensor 9 and the third flow sensor 10 and analyzes and determines to obtain the cleaning results, including cleaning success, cleaning failure and cleaning abnormality.

[0069] Specifically, flow fault judgment:

[0070] By analyzing the data from the flow sensor, operators can diagnose a number of possible causes of blockage, including the following:

[0071] Inaccurate flow readings: This may be caused by a damaged, clogged or contaminated flow sensor. Accurate flow readings are key to ensuring process stability, and any deviations may point to potential problems, including clogs.

[0072] Abnormal valve: If the valve is blocked, it may need to be cleaned or replaced. Circuit failure may also be one of the reasons for abnormal readings. Checking and repairing circuit problems is an important step to ensure the normal operation of the controller.

[0073] Sensor failure: Pressure sensors and flow sensors are key components for monitoring flow. If the sensor fails, it may result in an inability to read flow data correctly. In this case, the sensor may need to be calibrated or replaced.

[0074] Fluid pulsation: Fluid pulsation in the pipeline may cause the mass flow meter data to show abnormal jumps. This jump may be caused by fluid dynamic effects or external vibration sources, and the system needs to be adjusted to eliminate or reduce the impact of pulsation.

[0075] Specifically, repair treatment: Once the location and type of the fault are determined, the corresponding repair treatment can be carried out. For blockages, it may be necessary to clean or replace the pipe; for leaks, it may be necessary to replace seals or repair connections;

[0076] Anti-blocking cleaning: According to the cause of blockage or leakage, choose the appropriate cleaning method, such as flushing with solvent, piercing with needle, disassembling with tools, etc., to remove impurities or dried paint in the pipeline or spray gun to restore smoothness;

[0077] Anti-blocking retest: After cleaning, restart the spray robot, conduct a test spray, observe the spraying effect and the feedback signal of the sensor, and confirm whether the blockage or leakage has been eliminated. If there is still an abnormality, repeat the above steps until it is normal.

[0078] Specifically, spray robot paint pipeline cleaning:

[0079] The spray robot cleaning pipeline can be cleaned using a material storage box 5 or a clean water tank 6 .

[0080] 1) After spraying is completed, it is necessary to open the main valve 11-3, drain the paint in the pipeline, and then close the main valve 11-1;

[0081] 2) Take out the material storage box 5 and pour out the remaining material, and use a cleaning sponge to clean the inner wall of the material storage box 5;

[0082] 3) After the storage box 5 is cleaned, add an appropriate amount of clean water to the storage box 5, open the paint valve 11-1, and clean water passes through the spray pipe to clean the pipe. Open the spray gun 3 to spray the waste water from the cleaning pipe until the nozzle continues to spray clean water for 40-60s. There is no residual paint inside the spray gun 3, close the spray gun 3, and clean the waste water in the storage box 5;

[0083] 4) You can also directly add 7L of clean water into the clean water tank 6, open the clean water valve 11-2, and the clean water will pass through the spray pipe to clean the pipe. Open the spray gun 3 and spray the waste water from the cleaning pipe until the nozzle continuously sprays clean water for 40-60s. There is no residual paint inside the spray gun 3, and then close the spray gun 3.

[0084] Specifically, spray robot spray machine cleaning:

[0085] The spray robot cleaning spray machine can use the storage box 5 for cleaning.

[0086] The cleaning of the sprayer includes key components such as the nozzle, nozzle, and sprayer.

[0087] 1) Add an appropriate amount of clean water to the spray robot storage box 5 and put it into the spray robot; close the clean water valve 11-2, open the paint valve 11-1 and the sprayer; open the main valve 11-3 to allow the paint in the sprayer to reflux to prevent the paint from settling; after reflux for 30 seconds, close the main valve 11-3, the paint valve 11-2 and the sprayer; clean the waste water in the storage box 5;

[0088] 2) The printhead and nozzle may need to be disassembled for offline cleaning, or cleaned in place using a specific cleaning device;

[0089] 3) System inspection and drying: After the cleaning process is completed, check whether the system is clean and make sure there is no residual cleaning agent.

[0090] Specifically, there are several methods for feeding back the status of the cleaning action:

[0091] Cleaning success: If all monitored parameters are within normal range and no abnormalities are detected;

[0092] Cleaning failure: If one or more parameters do not meet the preset standards, or the system fails to complete the scheduled cleaning cycle;

[0093] Abnormal cleaning: If an unexpected situation is detected, such as a sudden drop in pressure, abnormal flow fluctuations, or temperature exceeding the limit;

[0094] Alarm: If the cleaning action detection results show blockage or leakage, or the cleaning time exceeds the preset threshold, an alarm signal can be issued through sound or light to remind users or supervisors to deal with it in time;

[0095] Display: If the detection results of the cleaning action show deviations or abnormalities, or the cleaning time is close to the preset threshold, the status of the cleaning action can be displayed on the screen or instrument to let the user or supervisor understand the progress and effect of the cleaning.

[0096] Specifically, cleaning records: If the detection results of the cleaning action show normal, or the cleaning is completed, the status of the cleaning action can be recorded through a database or log, including cleaning time, cleaning parameters, cleaning results, etc., to facilitate users or supervisors to query and analyze.

[0097] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0098] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A spray robot anti-blocking detection and cleaning system, characterized in that: include: An industrial computer (1), a communication module (2), a spray gun (3), a spray machine pump (4), a material storage box (5), a clean water tank (6), a pressure sensor (7), a first flow sensor (8), a second flow sensor (9) and a third flow sensor (10); The pressure sensor (7) is arranged on the spray gun (3); The spray gun (3) is connected to the spray pump (4) via a first pipeline, and a third flow sensor (10) is arranged on the first pipeline; The material storage box (5) and the clean water tank (6) are connected to the spray machine pump via a second pipeline and a third pipeline respectively; The first flow sensor (8) is arranged in the second pipeline, and the second flow sensor (9) is arranged in the third pipeline; The spray gun (3) and the spray pump (4) are respectively connected to the first output port of the communication module (2); The pressure sensor (7), the first flow sensor (8), the second flow sensor (9) and the third flow sensor (10) are respectively connected to the second output port of the communication module (2); The industrial computer (1) is communicatively connected with the communication module (2).

2. A spraying robot anti-blocking detection and cleaning system according to claim 1, characterized in that: The spray gun (3) is provided with a spray gun port (3-1), and the pressure sensor (7) is arranged at the connection between the spray gun port (3-1) and the first pipeline.

3. A spraying robot anti-blocking detection and cleaning system according to claim 1, characterized in that: A three-way valve (11) is arranged between the sprayer pump (4), the material storage box (5) and the clean water tank (6).

4. A spraying robot anti-blocking detection and cleaning system according to claim 3, characterized in that: The three-way valve (11) comprises a paint valve (11-1), a clean water valve (11-2) and a main valve (11-3).

5. A spraying robot anti-blocking detection and cleaning system according to claim 4, characterized in that: The paint valve (11-1) is connected to the second pipeline, the clean water valve (11-2) is connected to the third pipeline, and the main valve (11-3) is connected to the fourth pipeline connected to the sprayer pump (4).

6. A spray robot anti-blocking detection and cleaning method, characterized in that: A spray robot anti-blocking detection and cleaning system based on any one of claims 1 to 5 comprises an anti-blocking detection step and a cleaning step.

7. A spraying robot anti-blocking detection and cleaning method according to claim 6, characterized in that: Anti-blocking detection steps: S1-1. During the spraying process, the pressure sensor (7) collects the pressure data of the spray gun (3) in real time, the first flow sensor (8) collects the first flow data of the second pipeline between the storage box (5) and the spray pump (4) in real time, and the third flow sensor (10) collects the second flow data of the first pipeline between the spray pump (4) and the spray gun (3) in real time; the pressure data, the first flow data and the second flow data are sent to the industrial computer (1) through the communication module (2); S1-2. The industrial computer (1) compares the pressure data with the preset pressure range. If the pressure data deviates from the normal range, the industrial computer (1) triggers an alarm or automatically controls the spray gun (3) and the spray pump (4) to stop working; S1-3. The industrial computer (1) analyzes the pressure data, the first flow data and the second flow data, determines that the fault is a blockage or a gas leak, and further locates the fault and performs troubleshooting.

8. A spraying robot anti-blocking detection and cleaning method according to claim 6, characterized in that: Cleaning steps: S2-1. Setting of the cleaning program: According to different spraying construction process requirements, the parameters of the cleaning program are set by the industrial computer (1), including cleaning time and cleaning pressure; S2-2. Cleaning program trigger: The industrial computer (1) sends the corresponding cleaning parameters to the spray gun (3) and the spray pump (4) through the communication module (2); S2-3. Execution of the cleaning action: The water in the storage tank (5) or the water tank (6) is passed through the sprayer pump (4) to clean the pipes and the spray gun (3); S2-4. Feedback of cleaning action: After the cleaning procedure is completed, the industrial computer (1) obtains the real-time detection values ​​of the pressure sensor (7), the first flow sensor (8), the second flow sensor (9) and the third flow sensor (10) and analyzes and judges them to obtain the cleaning results, including cleaning success, cleaning failure and cleaning abnormality.

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