Electrostatic powder spraying gas supply control method and controller

Abstract

The invention provides an electrostatic powder spraying gas supply control method and a controller, and the method comprises the steps: S1, obtaining a gas pressure value and a gas flow value of an output side of a gas supply channel in real time, and obtaining a gas flow value of the output side of the gas supply channel according to a corresponding relation between a preset powder amount and a target gas pressure value and a target gas flow value; whether the air pressure numerical value and the air flow numerical value are equal to a target air pressure value and a target air flow value corresponding to the set powder amount or not is judged, and if yes, the air supply amount of the air supply channel is maintained; if not, whether the air pressure numerical value and the air flow numerical value are within a preset adjustable numerical value range or not is judged, if yes, the opening degree of the air supply channel is adjusted, and then the step S1 is executed; if not, it is judged that a fault occurs, fault reporting is carried out, and air inlet of the air supply channel is cut off. Closed-loop linkage regulation and control of the gas supply amount are achieved, a real-time monitoring and feedback mechanism for the actual gas supply condition is constructed, and the gas supply stability and the self-adaptability to different spraying processes can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of electrostatic powder spraying, and in particular to an electrostatic powder spraying air supply control method and a controller. Background Art

[0002] In the field of electrostatic powder spraying technology, the spray gun controller is the core control component, and its performance directly determines the powder suction efficiency, atomization effect and uniformity of the final coating during the spraying process. The spray gun controller controls the working state of the powder pump by adjusting the air supply, thereby affecting the powder delivery and atomization process.

[0003] At present, the commonly used control method for air supply regulation in the industry is to perform open-loop control of the air supply through a throttle valve, that is, the spray gun controller can only set the air flow rate by adjusting the opening of the throttle valve, but lacks real-time monitoring and feedback mechanism for the actual air supply or air pressure, and thus cannot dynamically regulate the air supply. There are technical defects such as insufficient air supply stability, lack of abnormal air supply response, and poor process adaptability. There is an urgent need for a spray gun controller technical solution that can detect the air supply status in real time, adaptively adjust the throttle valve opening, and has the ability to handle abnormal working conditions, so as to improve the process accuracy and stability of electrostatic powder spraying. Summary of the invention

[0004] In view of this, the purpose of the present invention is to provide an electrostatic powder spraying air supply control method and controller to solve the problem that the existing spray gun controller lacks real-time monitoring and feedback mechanism of the actual air supply volume or air pressure and cannot dynamically adjust the air supply volume.

[0005] In order to solve the above technical problems, the technical solution used in the present invention is:

[0006] The present invention provides an electrostatic powder spraying air supply control method, comprising the steps of:

[0007] S1, obtaining the air pressure value and the gas flow value at the output side of the air supply passage in real time, and judging whether the air pressure value and the gas flow value are equal to the target air pressure value and the target gas flow value corresponding to the set powder amount according to the correspondence between the preset powder amount and the target air pressure value and the target gas flow value, respectively, if yes, maintaining the air supply amount of the air supply passage; if no, entering step S2;

[0008] S2, judging whether the air pressure value and the gas flow value are within the preset adjustable value range, if so, adjusting the opening of the air supply passage according to the difference between the air pressure value and the corresponding target air pressure value and the difference between the gas flow value and the corresponding target gas flow value, and then entering step S1; if not, determining that a fault occurs, and entering step S3;

[0009] S3. Report a fault and cut off the air intake of the air supply duct.

[0010] Preferably, the preset adjustable value range includes a first value range for determining the air pressure value, and a second value range for determining the gas flow value;

[0011] The first numerical range is determined by the target gas pressure value according to a first preset ratio range, and the second numerical range is determined by the target gas flow value according to a second preset ratio range.

[0012] Further preferably, the first preset ratio range and the second preset ratio range are the same.

[0013] Further preferably, the first preset ratio ranges from 90% to 110%;

[0014] And / or, the second preset ratio ranges from 90% to 110%.

[0015] Preferably, in step S3:

[0016] The air pressure value and the gas flow value are acquired in real time within a preset time period, changes in the air pressure value and the gas flow value within the preset time period are analyzed, a fault type is determined according to the changes, and a fault report is made according to the determined fault type.

[0017] Preferably, in step S3:

[0018] The opening of the air supply duct is adjusted within a preset time period, and the gas flow value of the air supply duct is obtained in real time, the change of the gas flow value within the preset time period is judged, the fault type is determined according to the change, and then a fault report is made according to the determined fault type.

[0019] Preferably, the air supply duct is a delivery air duct or an atomization air duct.

[0020] Another object of the present invention is to provide an electrostatic powder spraying controller, comprising a main body, the main body is provided with an air supply duct, a throttle motor, a control panel, a fault reporting device, an air pressure sensor and a gas flow sensor, the air supply duct is provided with an input port for connecting to an air source and an output port for supplying air to the outside, a throttle valve connected to the air supply duct is provided between the input port and the output port, the throttle motor is connected to the throttle valve to adjust the air supply amount flowing out of the output port by adjusting the opening of the throttle valve;

[0021] The air pressure sensor and the air flow sensor are respectively connected to the air supply passage to correspondingly detect the air pressure and the air flow of the gas flowing out of the output port;

[0022] The air pressure sensor, gas flow sensor, fault reporting device and the throttling motor are also respectively connected to the control board signal. The control board is written with the above-mentioned electrostatic powder spraying air supply control method. The control board controls the air pressure sensor, gas flow sensor, fault reporting device and the throttling motor by running the method.

[0023] Preferably, the fault reporting device is an audible and visual alarm device, and the audible and visual alarm device performs fault reports of different audible and visual types according to different fault types determined by the controller.

[0024] Preferably, the fault reporting device is a display screen, and the display screen displays corresponding fault codes according to different fault types determined by the controller.

[0025] Compared with the prior art, the beneficial effects of the electrostatic powder spraying air supply control method described in the present invention are mainly reflected in:

[0026] The method of the present invention can calculate the target air pressure value and the target gas flow value by establishing a corresponding relationship between the preset powder amount and the target air pressure value and the target gas flow value, and then judge whether the current air supply volume can meet the spraying requirements through the air pressure value and the gas flow value obtained in real time, and classify and process the difference between the air pressure value and the gas flow value obtained in real time and the target air pressure value and the target gas flow value by setting a preset adjustable value range. On the one hand, the air pressure value and the gas flow value can be adjusted in real time to correspond to the corresponding target air pressure value and the target gas flow value. The flow value is consistent, and on the other hand, it can identify fault conditions and report and respond to faults. It has a fault reporting and response mechanism for abnormal gas supply, realizes closed-loop linkage control of the gas supply, and builds a real-time monitoring and feedback mechanism for the actual gas supply situation. It can improve the gas supply stability and adaptability to different spraying processes, avoids the inefficiency of manually adjusting the gas supply multiple times, improves the spraying work efficiency and the consistency of the spraying quality, and can solve the problem that the existing spray gun controller lacks a real-time monitoring and feedback mechanism for the actual gas supply or air pressure, and cannot dynamically control the gas supply.

[0027] Compared with the prior art, the beneficial effects of the electrostatic powder spraying controller described in the present invention are mainly reflected in: the controller of the present invention is provided with the air pressure sensor and the gas flow sensor in the air supply duct which can correspondingly detect the air pressure and gas flow of the gas flowing out of the output port, and the air pressure sensor and the gas flow sensor are respectively connected to the controller signal. The controller can realize real-time monitoring and dynamic regulation of the gas flowing out of the output port by running the above-mentioned electrostatic powder spraying air supply control method, which can improve the stability of the controller's external air supply and the adaptability to different spraying processes, and promote the improvement of spraying quality and spraying efficiency; by setting a fault reporting device, fault conditions in the operation process can be reported in time, which is convenient for the staff to promptly discover and respond to faults and quickly carry out maintenance work. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The above and other purposes, features and advantages of the present invention will become more clear by more specific description of the preferred embodiments of the present invention shown in the accompanying drawings. The same reference numerals indicate the same parts in all the accompanying drawings, and the accompanying drawings are not deliberately scaled to the actual size, and the focus is on illustrating the main purpose of the present invention.

[0029] Figure 1 A schematic flow chart of an electrostatic powder spraying air supply control method provided in an embodiment of the present invention;

[0030] Figure 2 Schematic diagram of the internal structure of an electrostatic powder spraying controller provided by an embodiment of the present invention Figure 1 ;

[0031] Figure 3 Schematic diagram of the internal structure of an electrostatic powder spraying controller provided by an embodiment of the present invention Figure 2 ;

[0032] Description of the drawings: main body 1, control panel 2, throttling motor 3, air supply duct 4, delivery air duct 410, atomizing air duct 420, input port 401, output port 402, air pressure sensor 5, gas flow sensor 6, throttle valve 7, display screen 8, adapter 9. DETAILED DESCRIPTION

[0033] The technical solution of the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments, so that those skilled in the art can better understand the present invention and implement it. However, the embodiments cited are not intended to limit the present invention. In the present embodiment, it should be understood that the orientations or positional relationships indicated by terms such as "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", and "outside" are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention.

[0034] It should be noted that when an element is considered to be "connected" to another element, it may be directly connected to the other element and integrated therewith, or there may be an intermediate element at the same time. The terms "installed", "one end", "the other end" and similar expressions used in the present invention are for illustrative purposes only.

[0035] This embodiment provides an electrostatic powder spraying gas supply control method, such as Figure 1 As shown, the steps include:

[0036] S1, obtaining the air pressure value and the gas flow value at the output side of the air supply passage 4 in real time, and judging whether the air pressure value and the gas flow value are equal to the target air pressure value and the target gas flow value corresponding to the set powder amount according to the correspondence between the preset powder amount and the target air pressure value and the target gas flow value, respectively, if yes, maintaining the air supply amount of the air supply passage 4; if not, entering step S2;

[0037] The air supply passage 4 is a conveying air passage 410, which is used to convey gas to the powder pump to generate negative pressure to extract powder; or it is an atomizing air passage 420, which is used to convey gas to the powder tube to atomize the powder in the powder tube evenly; of course, the conveying air passage 410 and the atomizing air passage 420 can be applied to the method of the present invention at the same time, and each air passage can be independently monitored and controlled;

[0038] S2, judging whether the air pressure value and the gas flow value are within the preset adjustable value range, if so, adjusting the opening of the air supply passage 4 according to the difference between the air pressure value and the corresponding target air pressure value and the difference between the gas flow value and the corresponding target gas flow value, and then entering step S1; if not, determining that a fault occurs, and entering step S3;

[0039] S3. Report a fault and cut off the air intake of the air supply duct 4.

[0040] This embodiment establishes a corresponding relationship between a preset powder amount and a target air pressure value and a target gas flow value, and can calculate the target air pressure value and the target gas flow value. Then, it can be judged whether the current air supply volume can meet the spraying requirements through the air pressure value and the gas flow value obtained in real time, and the difference between the air pressure value and the gas flow value obtained in real time and the target air pressure value and the target gas flow value is classified and processed by setting a preset adjustable value range. On the one hand, the air pressure value and the gas flow value can be adjusted in real time to make them correspond to the corresponding target air pressure value and the target gas flow value. On the one hand, it can identify fault conditions and report and respond to faults. It has a fault reporting and response mechanism for abnormal air supply, realizes closed-loop linkage control of air supply, and builds a real-time monitoring and feedback mechanism for actual air supply conditions. It can improve the stability of air supply and adaptability to different spraying processes, avoids the inefficient situation of changing the air supply by manually adjusting parameters multiple times, improves the spraying work efficiency and the consistency of spraying quality, and can solve the problem that the existing spray gun controller lacks a real-time monitoring and feedback mechanism for the actual air supply or air pressure, and is unable to dynamically control the air supply.

[0041] It should be noted that the correspondence between the preset powder amount and the target air pressure value and the target gas flow value needs to be obtained through experiments and summaries by the staff. For different powder types, coating thicknesses and spraying processes, the corresponding correspondence between the preset powder amount and the target air pressure value and the target gas flow value is also different. The method of the present invention is effective in batch spraying production.

[0042] In a preferred embodiment, the preset adjustable numerical range includes a first numerical range for determining the air pressure value, and a second numerical range for determining the gas flow value; the first numerical range is determined by the target air pressure value according to a first preset proportional range, and the second numerical range is determined by the target gas flow value according to a second preset proportional range.

[0043] In a further preferred embodiment, the first preset ratio range and the second preset ratio range are the same, that is, the preset ratio ranges of the target air pressure value and the target gas flow value are unified, which can simplify the calculation process and avoid possible adjustment conflicts such as the real-time air pressure value meets the requirements but the gas flow value does not meet the requirements, or the gas flow value meets the requirements but the air pressure value does not meet the requirements.

[0044] In a further preferred embodiment, the first preset ratio ranges from 90% to 110%; and / or, the second preset ratio ranges from 90% to 110%;

[0045] In another preferred embodiment, in step S3:

[0046] The air pressure value and the gas flow value are obtained in real time within a preset time period, the changes in the air pressure value and the gas flow value within the preset time period are analyzed, the fault type is determined according to the changes, and then a fault report is made according to the determined fault type.

[0047] If there is a leak in the air supply pipe that transports gas to the powder pump, the gas flow value will remain roughly unchanged, while the air pressure value will drop significantly; when the air supply pipe is blocked, the air pressure value will rise, and the gas flow value will be very small; since the air supply duct 4 usually includes at least the delivery air duct 410 and the atomizing air duct 420, when the powder tube of the powder pump is blocked, the delivery air duct 410 and the atomizing air duct 420 will both show an increase in air pressure and a very small gas flow value; the method of this embodiment utilizes the changing characteristics of air pressure and gas flow presented by these fault types, and can accurately identify the fault types of air supply pipe leakage, blockage and powder pump powder tube blockage.

[0048] In another preferred embodiment, in step S3:

[0049] The opening of the air supply passage 4 is adjusted within a preset period, and the gas flow value of the air supply passage 4 is obtained in real time, the change of the gas flow value within the preset period is judged, the fault type is determined according to the change, and then a fault report is made according to the determined fault type. When the throttle valve 7 is damaged, after the throttle valve 7 opening is controlled and adjusted, the gas flow value in the air supply passage 4 will remain unchanged. The method of this embodiment uses the characteristics of this type of fault type to accurately identify whether the throttle valve 7 is damaged.

[0050] It should be noted that the above preset time period can be set in seconds, such as 10s, 15s, 20s, etc.

[0051] In addition, an embodiment of an electrostatic powder spraying controller is provided, such as Figure 2 and Figure 3 As shown, the main body 1 is provided with an air supply passage 4, a throttle motor 3, a control panel 2, a fault reporting device, an air pressure sensor 5 and a gas flow sensor 6. The air supply passage 4 is provided with an input port 401 for connecting to an air source and an output port 402 for supplying air to the outside. A throttle valve 7 connected to the air supply passage 4 is provided between the input port 401 and the output port 402. The throttle motor 3 is connected to the throttle valve 7 so as to adjust the air supply amount flowing out of the output port 402 by adjusting the opening of the throttle valve 7.

[0052] The air pressure sensor 5 and the air flow sensor 6 are respectively connected to the air supply passage 4 to detect the air pressure and the air flow of the gas flowing out from the output port 402. Figure 2In the embodiment shown, the air supply passage 4 is connected to the air pressure sensor 5 or the gas flow sensor 6 by providing an adapter 9 in the air supply passage 4; the output port 402 is usually connected to the powder pump through an air pipe, and the connection points between the air pressure sensor 5 and the gas flow sensor 6 and the air supply passage 4 are located between the output port 402 and the outlet of the throttle valve 7;

[0053] The air pressure sensor 5, the gas flow sensor 6, the fault reporting device and the throttling motor 3 are also respectively connected to the control board 2 by signal. The control board 2 is written with the aforementioned electrostatic powder spraying gas supply control method. The control board 2 controls the air pressure sensor 5, the gas flow sensor 6, the fault reporting device and the throttling motor 3 through the operation method. The control board 2 receives the data information sent by the air pressure sensor 5 and the gas flow sensor 6 in real time, and controls the operation of the fault reporting device and the throttling motor 3 according to the data information.

[0054] The controller of this embodiment is provided with an air pressure sensor 5 and a gas flow sensor 6 in the air supply duct 4, which can detect the air pressure and gas flow of the gas flowing out from the output port 402 respectively. The air pressure sensor 5 and the gas flow sensor 6 are respectively connected to the controller signal. The controller can realize real-time monitoring and dynamic regulation of the gas flowing out from the output port 402 by running the above-mentioned electrostatic powder spraying air supply control method, which can improve the stability of the controller's external air supply and the adaptability to different spraying processes, and promote the improvement of spraying quality and spraying efficiency; by setting a fault reporting device, fault conditions in the operation process can be reported in time, which is convenient for the staff to discover and respond to faults in time, quickly carry out maintenance work, and avoid powder waste or equipment damage.

[0055] In a preferred embodiment, the fault reporting device is an audible and visual alarm device (not shown in the figure), which performs different audible and visual fault reports according to different fault types determined by the controller, so that the staff can grasp the fault type in time and quickly carry out targeted processing and maintenance.

[0056] In another preferred embodiment, the fault reporting device is a display screen 8, which displays the corresponding fault code according to the different fault types determined by the controller, intuitively informing the staff of the fault type, eliminating the need for manual judgment of the fault type, saving time in identifying the fault type and improving work efficiency and accuracy.

[0057] In this specification, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being "above", "above" or "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below", "below" or "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0058] In the description of this specification, the description with reference to the terms "preferred embodiment", "further embodiment", "other embodiments" or "specific example" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, unless they are contradictory.

[0059] Although the embodiments of the present application have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present application. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present application.

Claims

1. An electrostatic powder spraying air supply control method, characterized in that: Includes steps: S1, obtaining the air pressure value and the gas flow value at the output side of the air supply passage in real time, and judging whether the air pressure value and the gas flow value are equal to the target air pressure value and the target gas flow value corresponding to the set powder amount according to the correspondence between the preset powder amount and the target air pressure value and the target gas flow value, respectively, if yes, maintaining the air supply amount of the air supply passage; if no, entering step S2; S2, judging whether the air pressure value and the gas flow value are within a preset adjustable value range, and if so, adjusting the opening of the air supply passage according to the difference between the air pressure value and the corresponding target air pressure value and the difference between the gas flow value and the corresponding target gas flow value, and then entering step S1; If not, it is determined that a fault has occurred and the process goes to step S3; S3. Report a fault and cut off the air intake of the air supply duct.

2. The electrostatic powder spraying air supply control method according to claim 1, characterized in that: The preset adjustable value range includes a first value range for determining the gas pressure value, and a second value range for determining the gas flow value; The first numerical range is determined by the target gas pressure value according to a first preset ratio range, and the second numerical range is determined by the target gas flow value according to a second preset ratio range.

3. The electrostatic powder spraying air supply control method according to claim 2, characterized in that: The first preset ratio range and the second preset ratio range are the same.

4. The electrostatic powder spraying air supply control method according to claim 2, characterized in that: The first preset ratio ranges from 90% to 110%; And / or, the second preset ratio ranges from 90% to 110%.

5. The electrostatic powder spraying air supply control method according to claim 1, characterized in that: In step S3: The air pressure value and the gas flow value are acquired in real time within a preset time period, changes in the air pressure value and the gas flow value within the preset time period are analyzed, a fault type is determined according to the changes, and a fault report is made according to the determined fault type.

6. The electrostatic powder spraying air supply control method according to claim 1, characterized in that: In step S3: The opening of the air supply duct is adjusted within a preset time period, and the gas flow value of the air supply duct is obtained in real time, the change of the gas flow value within the preset time period is judged, the fault type is determined according to the change, and then a fault report is made according to the determined fault type.

7. The electrostatic powder spraying air supply control method according to claim 1, characterized in that: The air supply passage is a delivery air passage or an atomization air passage.

8. An electrostatic powder spraying controller, characterized in that: The main body is provided with an air supply passage, a throttle motor, a control panel, a fault reporting device, an air pressure sensor and a gas flow sensor. The air supply passage is provided with an input port for connecting to an air source and an output port for supplying air to the outside. A throttle valve connected to the air supply passage is provided between the input port and the output port. The throttle motor is connected to the throttle valve to adjust the air supply amount flowing out of the output port by adjusting the opening of the throttle valve. The air pressure sensor and the air flow sensor are respectively connected to the air supply passage to correspondingly detect the air pressure and the air flow of the gas flowing out of the output port; The air pressure sensor, gas flow sensor, fault reporting device and the throttling motor are also respectively connected to the control board signal, and the control board is written with an electrostatic powder spraying air supply control method as described in any one of claims 1 to 7, and the control board controls the air pressure sensor, gas flow sensor, fault reporting device and the throttling motor by running the method.

9. An electrostatic powder spraying controller according to claim 8, characterized in that: The fault reporting device is an audible and visual alarm device, and the audible and visual alarm device performs fault reports of different audible and visual types according to different fault types determined by the controller.

10. An electrostatic powder spraying controller according to claim 8, characterized in that: The fault reporting device is a display screen, and the display screen displays corresponding fault codes according to different fault types determined by the controller.

Images