Automatic zinc ingot adding system and method for hot-dip galvanizing

Abstract

The present invention relates to a system and method for automatically adding zinc ingots for hot-dip galvanizing, belonging to the technical field of hot-dip galvanizing. The system comprises a robot for clamping zinc ingots, a slide conveyor device for conveying zinc ingots, a visual monitoring component, and a laser ranging level sensor installed in the zinc pot for monitoring the liquid level of the zinc pot. The slide conveyor device comprises a slide body, a blocking mechanism, and a release mechanism. The slide body is made of high-temperature resistant material, with one side close to the robot operating area and the other side extending to above the zinc liquid in the zinc pot. The zinc ingot automatically slides to the end of the slide body under the action of its own gravity on the slide body. The blocking mechanism is located at the end of the slide body and is used to temporarily block the zinc ingot above the zinc liquid in the zinc pot for drying. After the zinc ingot is dried, the robot operates to release the zinc ingot. The present invention realizes the automatic sliding in and drying of zinc ingots, is suitable for large-scale hot-dip galvanizing production, and has the advantages of high efficiency, safety, and continuous operation.

Description

Technical Field

[0001] The present invention relates to the technical field of hot-dip galvanizing, and in particular to a system and method for automatically adding zinc ingots for hot-dip galvanizing, and is particularly suitable for a system in which a robot grabs zinc ingots and automatically slides the zinc ingots into a zinc pot. Background Art

[0002] In the hot-dip galvanizing production process, timely replenishing zinc ingots into the zinc pot for smelting is a key link to ensure the continuous galvanizing process. The addition of zinc ingots has a direct impact on the temperature of the zinc pot and the quality of galvanizing. In order to avoid the "zinc explosion" and "zinc splashing" phenomena caused by temperature fluctuations and uneven composition of the plating solution, when adding zinc ingots, the zinc ingots should be placed on the edge of the zinc pot for preheating and drying (the edge temperature is about 200°C), and then the zinc ingots should be slowly put into the zinc pot to ensure temperature stability and uniform composition. The traditional method of manually adding zinc ingots has problems such as low efficiency, high labor intensity, and high safety hazards. In recent years, with the development of automation technology, robots have gradually been introduced into the zinc ingot adding system to improve efficiency and safety. However, in the existing technology, the method of the robot grabbing the zinc ingot and directly placing it into the zinc pot has the following problems:

[0003] 1. Insufficient drying of zinc ingots: The zinc ingots need to be fully dried before entering the zinc pot to avoid moisture entering the zinc pot and causing safety hazards such as explosion.

[0004] 2. Liquid level measurement limitations: Laser ranging sensors are subject to strong reflections from the zinc bath surface and interference from dust, resulting in inaccurate measurements. Existing literature uses optical filters to address specular reflection issues. However, the high temperature and dusty environment of the zinc bath easily contaminates the filter with zinc vapor or oxides, reducing light transmittance and requiring frequent maintenance. Furthermore, optical filters can cause signal distortion due to fluctuations in the zinc bath surface or changes in vapor concentration.

[0005] 3. Robot operation limitations: Due to the high temperature of the zinc pot (which can reach 450°C or higher), the robot must maintain a certain distance from the pot, making it impossible to accurately place zinc ingots directly. Furthermore, adding too much zinc ingots can cause zinc explosions, leading to more serious safety accidents.

[0006] 4. Difficulty in continuous operation: In traditional systems, the addition and drying processes of zinc ingots cannot be efficiently connected, affecting production efficiency.

[0007] Therefore, there is an urgent need for an automatic zinc ingot adding system and method for hot-dip galvanizing that can solve the above problems and achieve efficient, safe and continuous addition of zinc ingots. Summary of the Invention

[0008] The purpose of the present invention is to provide a system and method for automatically adding zinc ingots for hot-dip galvanizing, which realizes the drying of zinc ingots and their automatic sliding into the zinc pot through a slide conveyor device, and cooperates with the control unit of the robot to solve the problems of insufficient drying of zinc ingots, limited robot operation and difficulty in continuous operation in the prior art.

[0009] To achieve the above object, the technical solution adopted by the present invention is:

[0010] In a first aspect, the present invention provides an automatic zinc ingot adding system for hot-dip galvanizing, comprising a robot for gripping the zinc ingots, a slide conveyor for conveying the zinc ingots, a visual monitoring component, and a laser ranging level sensor installed in a zinc pot for monitoring the liquid level of the zinc pot;

[0011] The slide conveying device includes a slide body, a blocking mechanism and a releasing mechanism;

[0012] The slide body is made of high-temperature resistant material, with one side close to the robot operating area and the other side extending above the zinc liquid in the zinc pot; the zinc ingot automatically slides to the end of the slide body under the action of its own gravity;

[0013] The blocking mechanism is located at the end of the slide body and is used to temporarily block the zinc ingot above the zinc liquid in the zinc pot for drying;

[0014] The release mechanism is linked with the blocking mechanism, and is used for releasing the zinc ingot by the robot after the zinc ingot is dried;

[0015] The laser ranging liquid level sensor is linked to the robot for control. The laser ranging liquid level sensor transmits real-time data of the zinc pot liquid level to the robot's control unit within a set time interval. The control unit determines whether to trigger the instruction to replenish zinc ingots based on the set upper and lower limits of the liquid level.

[0016] The visual monitoring component is used to identify the position, direction and surface condition of zinc ingots in the zinc pile;

[0017] The control unit is electrically connected to the visual monitoring component and determines whether the robot grabs the monitored zinc ingot according to the detection result of the visual monitoring component.

[0018] Furthermore, the front and rear of the slide body are supported by a slide support structure, which includes a front-end support structure close to the robot operating area, a rear-end support structure close to the zinc pot, and a fixed bracket. The front-end support structure and the rear-end support structure have the same structure but different heights, forming a height difference, which makes the slide body appear sloped; a plurality of rollers are provided on the slide body, and the end of the slide body facing the zinc pot is lower than the end facing the robot operating area, and the zinc ingot automatically slides to the end of the slide body through the rollers.

[0019] Furthermore, the height difference between the front and rear end support structures can be freely adjusted.

[0020] Furthermore, the blocking mechanism and the releasing mechanism are linked by a steel wire, and the releasing mechanism loosens or tightens the steel wire to cause the baffle of the blocking mechanism to fall or rise; the robot controls the loosening or tightening of the steel wire connecting the releasing mechanism and the blocking mechanism through the executing component, thereby controlling the falling or lifting of the blocking mechanism to achieve the blocking or release of the zinc ingot.

[0021] Furthermore, the system also includes a nitrogen protection air curtain device, which is fixed to the bottom of the lens of the laser ranging liquid level sensor through a bracket. The nitrogen protection air curtain device includes a hollow nitrogen distribution pipe and a closed circular tube. The closed circular tube is sleeved on the outside of the nitrogen distribution pipe, and the area between the nitrogen distribution pipe and the closed circular tube is sealed at both ends, forming an annular air inlet cavity between the nitrogen distribution pipe and the closed circular tube.

[0022] An air inlet interface is provided in the middle of the closed circular tube;

[0023] A plurality of groups of small-hole nozzles with nozzles facing the interior of the nitrogen distribution pipe are arranged in the height direction of the nitrogen distribution pipe, and a plurality of small-hole nozzles are evenly arranged in each group along the circumference of the nitrogen distribution pipe.

[0024] Furthermore, the bracket is a structure that allows fine adjustment of the position and angle of the nitrogen distribution pipe.

[0025] Furthermore, the system also includes a cloud, which includes a cloud server, a user access interface, a cloud database, a statistical module and a time series prediction model;

[0026] The cloud database contains a liquid level data table, a zinc ingot usage log table, and a visual image information table;

[0027] The liquid level data table stores the timestamp and real-time liquid level value, and the zinc ingot usage log table records the amount of zinc ingot added each time and the corresponding time;

[0028] The statistics module is used to automatically summarize zinc usage;

[0029] The time series forecasting model is used to predict future zinc ingot consumption trends based on historical zinc consumption data;

[0030] Communicate with terminals or users through the user access interface.

[0031] In a second aspect, the present invention provides a method for automatically adding zinc ingots for hot-dip galvanizing, wherein the method uses the automatic zinc ingot adding system for hot-dip galvanizing and comprises the following steps:

[0032] The inclination angle of the slide body when the zinc ingot automatically slides to the bottom of the slide body is calculated using the deadweight of the zinc ingot to be grasped and the rolling friction coefficient of the sliding body. The slide body is adjusted to the calculated inclination angle and the time t1 when the zinc ingot reaches the blocking mechanism is calculated.

[0033] The laser ranging liquid level sensor transmits the real-time data of the zinc pot liquid level to the robot's control unit within the set time interval.

[0034] The control unit compares the real-time data of the zinc pot liquid level with the set upper and lower limits of the liquid level threshold. If the real-time data of the zinc pot liquid level is greater than the upper limit of the liquid level threshold, it sends a command to the robot to replenish zinc ingots;

[0035] When the robot receives the instruction to replenish the zinc ingot, the control unit obtains the data of the visual monitoring component in real time to determine whether to grab the current zinc ingot. If the requirements are met, the zinc ingot is grabbed;

[0036] In the initial state, the blocking mechanism remains in the falling state, the passage of the zinc ingot in the blocking mechanism is closed, and the passage of the zinc ingot in the releasing mechanism is opened;

[0037] The robot places the grabbed zinc ingot on the slide body of the slide conveyor. The initial time t0 of the zinc ingot being placed on the slide body is recorded. After that, the zinc ingot automatically slides toward the zinc pot under its own gravity. The time is continuously recorded during this process. When the time pointer of the control unit reaches t0+t1, the zinc ingot reaches the end of the slide body and is prevented from entering the zinc pot by the blocking mechanism.

[0038] Set the drying time t3. When the time pointer of the control unit reaches t0+t1+t3, the zinc ingot is effectively dried at its current position by utilizing the residual heat of the zinc liquid. When the drying is completed, the robot controls the release mechanism to lift the blocking mechanism and release the dried zinc ingot.

[0039] After the zinc ingot falls into the zinc pot, the robot releases the release mechanism and returns to the initial state. The time is reset and it continues to determine whether the zinc ingot needs to be added. When the real-time data of the zinc pot liquid level is lower than the lower limit of the liquid level threshold, the robot stops adding zinc ingots and resets.

[0040] Compared with the prior art, the present invention has the following beneficial effects:

[0041] 1. Automated operation: The system of the present invention combines the robot's control unit with visual monitoring, the operation of the release mechanism, and the laser ranging liquid level sensor. The visual monitoring, laser ranging liquid level sensor, slideway conveyor and robot work together to realize the automatic grasping, sliding in and releasing of zinc ingots, reducing manual intervention and improving production efficiency.

[0042] 2. Accurate Measurement: A nitrogen protective air curtain protects the optical path, forming a "gas isolation layer." This active protection solves the core issue of specular reflection in zinc liquid, improving the stability and accuracy of liquid level measurement. Furthermore, it offers greater reliability and maintenance advantages in high-temperature, highly contaminated zinc pot environments, making it particularly suitable for long-term continuous operation.

[0043] 3. Efficient drying: The slide conveyor device in the present invention relies on the height difference to make the zinc ingot automatically slide to the blocking mechanism. The zinc ingot stays above the zinc pot and is dried, ensuring that the zinc ingot is fully dehydrated before entering the zinc pot, thereby improving safety.

[0044] 4. Continuous operation: The present invention uses the overall control of the control unit to seamlessly connect the addition and drying processes of zinc ingots, support continuous operation, and meet the needs of large-scale production.

[0045] 5. Simple and reliable structure: The entire slide conveyor device of the present invention is made of high-temperature resistant materials, and the lifting and falling of the blocking mechanism can be controlled without introducing additional sensors, motors and other electrical components, which reduces the assembly cost of the system. The structure is simple and durable, and is more suitable for high-temperature environments.

[0046] The system and method of the present invention significantly reduce manual operations and can utilize advanced equipment such as robotics, laser ranging liquid level sensors, and visual recognition to intelligently replenish zinc liquid in real time throughout the entire process, thereby improving production efficiency and eliminating potential safety hazards. Furthermore, on the one hand, the present invention uses a laser ranging liquid level sensor to monitor the zinc liquid level in real time and promptly trigger the robot to replenish zinc, thereby ensuring the stability of the zinc liquid and avoiding problems of excessive / insufficient zinc liquid. On the other hand, the dried zinc ingots are slowly released into the pot (on the one hand, the inclination angle of the slide can be optimally adjusted according to the specifications of the zinc ingots; on the other hand, the zinc ingots are blocked at the end of the slide and released after drying. At this time, the zinc ingots begin to slide from a stationary state into the zinc pot, and can slowly slide into the zinc pot), thereby avoiding zinc explosion, reducing fluctuations in the liquid level in the zinc pot, and effectively ensuring the uniformity of the zinc liquid coating. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 The figure is a schematic structural diagram of an embodiment of an automatic zinc ingot adding system for hot-dip galvanizing according to the present invention.

[0048] Figure 2 This is a schematic structural diagram of a slide conveying device according to an embodiment of the present invention.

[0049] Figure 3 This is a schematic diagram of a slide front end support structure according to an embodiment of the present invention.

[0050] Figure 4 This is a front structural schematic diagram of a blocking mechanism according to an embodiment of the present invention.

[0051] Figure 5 This is a schematic side structural diagram of a blocking mechanism according to an embodiment of the present invention.

[0052] Figure 6 This is a front structural schematic diagram of a release mechanism according to an embodiment of the present invention.

[0053] Figure 7 This is a side structural diagram of a release mechanism according to an embodiment of the present invention.

[0054] Figure 8 This is a schematic diagram of the overall structure of a nitrogen protection air curtain device according to an embodiment of the present invention.

[0055] Figure 9 This is a schematic structural diagram of a nitrogen distribution pipe of a nitrogen protection gas curtain device according to an embodiment of the present invention.

[0056] Figure 10 This is a perspective structural diagram of a nitrogen protective air curtain device according to an embodiment of the present invention.

[0057] Among them, 1 is the zinc pot, 2 is the visual monitoring component, 3 is the slide conveyor, 4 is the robot, 5 is the zinc pile, and 6 is the fixture;

[0058] 31 is the slide body, 32 is the slide support structure, 33 is the blocking mechanism, 34 is the release mechanism; 311 is the roller;

[0059] 321 is the base, 322 is the support column, 323 is the adjustment component, 324 is the connecting component, 3221 is the large hollow square steel tube, 3231 is the small hollow square steel tube, 3232 is the screw lifting platform; 3233 is the hand wheel;

[0060] 331 is a small support frame, 332 is a baffle, 333 is a pulley, 334 is a rotating screw component; 3341 is a screw, 3342 is a screw bearing, 3343 is a screw cover; 3321 is a steel plate;

[0061] 342 is a press plate, 341 is a press plate connector, and 3411 is a wire hole;

[0062] 71 nitrogen distribution pipe; 711 small hole nozzle; 72 closed round tube; 721 air inlet interface. DETAILED DESCRIPTION

[0063] The present invention is described in detail below with reference to the embodiments and drawings, but they are not intended to limit the scope of protection of the present application.

[0064] Example 1:

[0065] This embodiment is used for the automatic zinc ingot adding system of hot dip galvanizing (refer to Figure 1), including a robot 4 for gripping zinc ingots, a slide conveyor 3 for transporting zinc ingots, a visual monitoring component 2, and a laser ranging level sensor (not shown in the figure) installed in the zinc pot 1 for monitoring the liquid level of the zinc pot.

[0066] The slide conveyor (see Figure 2 ) includes a slide body 31, a blocking mechanism 33 and a release mechanism 34;

[0067] The slide body is made of high-temperature resistant material, with one side close to the robot operating area and the other side extending above the zinc liquid in the zinc pot; the zinc ingot automatically slides to the end of the slide body under the action of its own gravity;

[0068] The blocking mechanism is located at the end of the slide body and is used to temporarily block the zinc ingot above the zinc liquid in the zinc pot for drying;

[0069] The release mechanism is linked with the blocking mechanism, and is used for releasing the zinc ingot by the robot after the zinc ingot is dried;

[0070] The laser ranging liquid level sensor is linked to the robot for control. The laser ranging liquid level sensor transmits real-time data of the zinc pot liquid level to the robot's control unit within a set time interval. The control unit determines whether to trigger the instruction to replenish zinc ingots based on the set upper and lower limits of the liquid level.

[0071] The visual monitoring component is used to identify the position, direction and surface condition of the zinc ingots in the zinc pile 5;

[0072] The control unit is electrically connected to the visual monitoring component and determines whether the robot grabs the monitored zinc ingot according to the detection result of the visual monitoring component.

[0073] Example 2:

[0074] In this embodiment, the slide conveying device includes a slide body 31 , a slide support structure 32 , a blocking mechanism 33 and a releasing mechanism 34 .

[0075] The slide body 31 is made of high-temperature resistant material, with one side connected to the robot operation area and the other side extending to above the zinc liquid in the zinc pot; the roller 311 is arranged on the slide body 31, which is used to make the zinc ingot automatically slide to the end of the slide; the blocking mechanism 33 is arranged at the end of the slide, which is used to temporarily block the zinc ingot 5 above the zinc pot and use the hot air flow above the zinc liquid in the zinc pot to dry the zinc ingot. The temperature of the zinc liquid in the zinc pot is about 450°C, and the temperature of the convective hot air above it is usually about 200-300°C; the release mechanism 34 is linked with the blocking mechanism 33, which is used to release the zinc ingot after the zinc ingot is dried.

[0076] Supported by the slide support structure, the end of the slide body facing the zinc pot is lower than the end facing the robot operation area, and the zinc ingot automatically slides to the end of the slide body through the roller 311.

[0077] Example 3:

[0078] In this embodiment, the slideway support structure 32 (see Figure 2 and Figure 3 The slideway consists of a front support structure near the robot's operating area, a rear support structure near the zinc pot, and a fixed bracket. The two support structures are identical in construction but at different heights. This height difference creates a sloped shape for the slideway, facilitating the automatic descent of the zinc ingots along the slideway under gravity. The front and rear support structures are connected by the fixed bracket, strengthening the connection between the slideway and the support structure.

[0079] The front end support structure includes a base 321, a support column 322, an adjustment component 323 and a connecting component 324. The base is fixed to the ground or a work platform by bolts.

[0080] The support column 322 comprises a large hollow square steel tube 3221 fixedly connected to the base. The lower end of the support column 322 is connected to the base 321, and the upper end is connected to the adjustment component 323. The adjustment component comprises a small hollow square steel tube 3231 and a screw lift 3232. The small hollow square steel tube 3231 can be telescopically inserted into the large hollow square steel tube 3221. The screw lift 3232 is driven by rotating a handwheel, which can precisely adjust the depth of the small hollow square steel tube 3231 into the large hollow square steel tube 3221, thereby achieving flexible adjustment of the support structure's height. The upper ends of the two small hollow square steel tubes 3231 are connected to a connecting component 324 for fixing to the slide body.

[0081] Specifically, the drive is achieved by rotating a handwheel. The rotation of handwheel 3233 drives the linear motion of the screw connected to the handwheel, thereby precisely controlling the depth to which the small hollow square steel tube 3231 extends into the large hollow square steel tube 3221. This nested structure not only ensures structural stability but also provides a sufficient adjustment range to accommodate the height requirements of different working environments. The screw lift is manually adjusted by a handwheel, avoiding the need for precision instruments such as electronic controls during automatic adjustment, which would increase the cost of high-temperature resistance.

[0082] The slideway support structure of this invention achieves flexible height adjustment through the telescopic coordination of large and small hollow square steel tubes and the precision drive of the screw lift platform. Its ingenious design and simple operation not only accurately adapt to the height requirements of different working environments, but also ensures the stability and reliability of the slideway body during the zinc ingot sliding process. During the initial use of the galvanizing line, the height of the front and rear support structures is adjusted according to the position of the zinc pot and the robot operating area on the line. The height adjustment is no longer required during the subsequent feeding process.

[0083] Example 4:

[0084] In this embodiment, the blocking mechanism 33 (see Figure 4 and Figure 5 ) includes a small support frame 331, a baffle 332, a pulley 333 and a rotating screw component 334. The small support frame 331 is made of high-temperature resistant stainless steel material, has an N-shaped structure, and is fixedly connected to the slide body through the bottom of the small support frame. Two pulleys 333 are symmetrically installed on the upper end of the small support frame 331 to reduce the friction resistance of the steel wire. The small support frame 331 is provided with a rotatable rotating screw component 334 in the middle part in the vertical direction. The rotating screw component 334 is composed of a screw 3341, a screw bearing 3342 and a screw cover 3343. The screw cover 3343 semi-covers the screw bearing 3342 and the screw 3341 to play a role of protection and fixation. The upper end of the screw cover 3343 extends toward the zinc pot and is fixedly connected to the baffle 332. One end of the baffle 332 is connected to the screw cover 3343, and the other end is connected to a steel plate 3321 of equal width in the vertical direction. The lower end of the steel plate 3321 is used to block the zinc ingot, and the upper end has a through hole for connecting the steel wire, and the through hole is aligned with the two pulleys in the horizontal direction.

[0085] Specifically, a blocking mechanism is located at the end of the slide body and fixes the position of the small support frame base according to the length of the zinc ingot. This ensures that when the baffle is lowered, the zinc ingot is located inside the baffle and does not fall into the zinc pot. When the baffle 332 is in a state of powerlessness, it temporarily blocks the zinc ingot at the end of the slide by its own gravity, allowing it to remain above the zinc pot for a period of time, allowing the hot air flow above the zinc liquid to dry the zinc ingot.

[0086] A steel wire connects the pulley on the small support frame to the through-holes in the baffle and the release mechanism. Loosening or tightening the wire causes the baffle to drop or rise. Once the zinc ingot is dried, pulling the wire lifts the baffle, allowing the ingot to slide freely. This simple and reliable structure effectively controls the ingot's drop timing, ensuring precise positioning and release within the slide.

[0087] The initial state is that the lower part of the baffle is attached to the slide body, and at this time the passage of the zinc ingot in the blocking mechanism is closed.

[0088] Example 5:

[0089] In this embodiment, the release mechanism (see Figure 6 and Figure 7 ) also includes a small support frame, a pulley installed on the small support frame and a rotating screw component installed in the middle of the small support frame. In addition, it also includes a pressing plate 342 and a pressing plate connecting piece 341.

[0090] The small support frame of the release mechanism has the same structure as the small support frame 331 of the blocking mechanism, and maintains the same height and parallel configuration; the lower end of the small support frame of the release mechanism is fixedly connected to the slideway body 31 to ensure overall stability, and two pulleys are symmetrically installed on the upper end to reduce frictional resistance during the operation of the wire, thereby improving the smoothness and efficiency of the mechanism operation;

[0091] The upper portion of the screw cover plate in the rotating screw component of the release mechanism is fixed to the press plate connecting piece, which extends toward the robot operating area and is symmetrically provided with steel wire holes for guidance. The press plate connecting piece is fixedly connected to the press plate; one end of the two steel wires is fixed to the steel wire holes 3411 on the press plate connecting piece, and the other end passes through two pulleys along the length of the slide body and is fixed to the through-holes on the baffle, ensuring stable connection and guidance of the steel wires;

[0092] The pressing plate 342 is made of high-temperature resistant stainless steel to ensure its durability in high-temperature environments. The robot presses the pressing plate 342 to realize the rise and fall of the baffle 332 of the blocking mechanism 33, thereby controlling the retention and release of the zinc ingot.

[0093] Specifically: The steel wire passes through the blocking mechanism and the release mechanism. When the zinc ingot is dried, the robot presses the button to realize the linkage between the blocking mechanism and the release mechanism, so that the baffle can effectively control the release of the zinc ingot. In this case, the button is the actuator.

[0094] Example 6:

[0095] This embodiment is used for a method of automatically adding zinc ingots to hot-dip galvanizing, using the above-mentioned system, including a robot for gripping the zinc ingots, a slide conveyor for transporting the zinc ingots, a visual monitoring component, and a laser ranging level sensor installed in the zinc pot for monitoring the zinc pot liquid level. Each component is controlled by a control unit of the robot;

[0096] The slide conveying device includes a slide body 31, a slide support structure 32, a blocking mechanism 33, and a release mechanism 34;

[0097] The slide body 31 is made of high temperature resistant material, one end of which is connected to the robot operation area and the other end extends above the zinc liquid in the zinc pot;

[0098] A plurality of rollers 311 are provided on the slide body, and the zinc ingots automatically slide to the end of the slide body through the rollers 311 .

[0099] The slide support structure 32 includes a front support structure near the robot's operating area, a rear support structure near the zinc pot, and a fixed bracket. The support structures at both ends are identical in construction but at different heights. This height difference creates a sloped shape for the slide, facilitating the automatic descent of the zinc ingots by gravity. The fixed bracket connects the support structures at both ends to strengthen the connection between the slide and the support structure.

[0100] The front end support structure includes a base 321, a support column 322, and an adjustment component 323. The base is fixed to the ground or a work platform by bolts.

[0101] The control unit is electrically connected to the robot. The robot is responsible for grabbing the zinc ingot and controlling the blocking mechanism through the release mechanism. The zinc ingot is released or blocked by controlling the blocking mechanism to lift or fall, thereby realizing fully automated operation.

[0102] All components in the present invention are made of high-temperature resistant materials, preferably those that can withstand temperatures of 400-500°C. The information flow between the slide conveyor, the robot, and the laser ranging liquid level sensor is real-time, ensuring that the zinc ingots can be released and added to the zinc pot in optimal conditions for the subsequent galvanizing process. The specific workflow is as follows:

[0103] 1. Linkage control of laser ranging liquid level sensor and robot

[0104] Working Principle: The laser level sensor utilizes laser ranging technology to determine the liquid level by emitting a laser beam to the surface of the zinc solution, receiving the reflected light, and calculating the laser's round-trip time. The laser level sensor is equipped with a high-temperature protective cover to ensure proper operation in high-temperature environments, avoid external interference, and improve measurement stability and accuracy. The laser level sensor is placed in the zinc pot, above the zinc solution, and remains immersed in the zinc solution throughout its operation.

[0105] Control Flow:

[0106] 1. Data Collection

[0107] The laser ranging level sensor continuously acquires and calculates the height of the zinc liquid surface and sends the data to the robot's control unit at set time intervals (such as every 1 second).

[0108] 2. Threshold judgment

[0109] The control unit sets an upper limit and a lower limit of the liquid level threshold (in this embodiment, the lower limit (minimum threshold) of the liquid level threshold is 1.5 m, and the upper limit (maximum threshold) of the liquid level threshold is 1.6 m). That is, when the liquid level value is greater than 1.6 m, the system will consider that zinc needs to be replenished, and when the liquid level value is less than 1.5 m, zinc does not need to be replenished.

[0110] The control unit compares the real-time liquid level data with the upper and lower limits of the liquid level threshold, and automatically determines whether to issue an instruction to replenish zinc ingots.

[0111] 3. Automatic instruction generation:

[0112] Once it detects that the liquid level value is greater than 1.6m, the control unit immediately generates a "replenish zinc ingot" instruction and sends the instruction to the robot.

[0113] 4. Status feedback and monitoring

[0114] The control unit checks the liquid level data multiple times to ensure that the command will not be falsely triggered due to liquid level fluctuations. That is, when it detects that zinc ingots need to be replenished, at least three consecutive samples are taken before the set time interval is reached. If the liquid level value fluctuations of multiple samples do not exceed 5%, it is considered a false alarm and the "replenish zinc ingot" command is canceled. Otherwise, the "replenish zinc ingot" command continues to be executed.

[0115] 2. Linkage control between visual monitoring components and robots

[0116] How it works

[0117] The visual monitoring component 2 monitors the zinc pile 5 in real time through a 3D industrial camera, and uses advanced image processing algorithms and deep learning models to identify the position, direction and surface condition of the zinc ingots.

[0118] 1. Photographing and recognition

[0119] After the robot's control unit issues an instruction to replenish zinc ingots, the robot first moves to the designated position and immediately sends an instruction to the visual monitoring component to start the visual monitoring component's 3D industrial camera to shoot the zinc stack area.

[0120] The 3D industrial camera captures the position data of zinc ingots at a high frequency and supports multi-angle shooting to ensure accurate identification.

[0121] 2. Object Detection

[0122] The captured images are analyzed to identify the specific position coordinate information and status data of each zinc ingot, wherein the status data indicates whether the zinc ingot is on the front or back side.

[0123] 3. Data transmission and processing

[0124] The specific position coordinate information and status data of the identified zinc ingot are quickly transmitted back to the robot's control unit through a high-bandwidth channel.

[0125] If the recognized information is insufficient (for example, the returned coordinate information is 0), a "retake photo" request is sent to ensure the most accurate data.

[0126] 4. Crawl decision:

[0127] The robot's control unit determines the feasibility of grasping based on the data sent back by the visual monitoring component and selects a suitable clamp 6 (this embodiment uses a high-temperature adjustable clamp, which is an existing product of the applicant company).

[0128] 3. Linkage control between slide conveyor and robot

[0129] Control principle: The slide conveyor ensures the effective transportation and drying of zinc ingots through gravity and mechanical design. The slide body is provided with a blocking mechanism 33 and a release mechanism 34 to ensure that the zinc ingots can stay properly above the zinc pot when they reach the zinc pot for high-temperature drying.

[0130] 1. Zinc Ingot Grabbing and Placement: The robot grasps the zinc ingot using a clamp and places it steadily on the slide. Rollers 311 on the slide automatically slide the ingot toward the zinc pot under their own weight. The presence of the rollers effectively reduces friction between the ingot and the slide, ensuring smooth movement.

[0131] 2. Drying treatment: When the zinc ingot reaches the end of the slide body, the baffle 332 of the blocking mechanism 33 blocks it and uses the residual heat of the zinc liquid to effectively dry it.

[0132] 3. Release Mechanism: Once the set drying time t3 is reached, the robot activates the release mechanism 34 and presses the release plate 342. The pressing action of the release plate 342, coupled with the steel wire blocking mechanism 33, lifts the baffle 332, releasing the dried zinc ingot. The drying time is directly related to the temperature within the pot and the size of the zinc ingot. It can be set based on actual production requirements. The average drying time for zinc ingots is typically used as a guide. For example, when the zinc solution temperature is maintained at 450°C and the convection hot air temperature above it is between 200–300°C, a 10 kg zinc ingot can typically be dried within 1–5 minutes. If the zinc ingot is not too damp, a 2-minute cycle can be used to adjust the production schedule. If the zinc ingot is slightly damp, a 5-minute cycle can be used. The specific drying time can be determined based on the actual production line conditions.

[0133] 4. Baffle Reset and Next Cycle: After the zinc ingot is released, the robot releases push plate 342, opening the ingot's passage through the release mechanism. Baffle 332 automatically drops under gravity, returning to its initial position against the slide body, closing the ingot's passage through the blocking mechanism. Baffle 332's reset allows it to block the next zinc ingot, thus starting a new cycle of drying and releasing the ingot.

[0134] 5. Overall coordination: The control unit compares the relative size of the real-time data of the zinc pot liquid level with the set upper and lower limits of the liquid level threshold. When the real-time data of the zinc pot liquid level is less than the lower limit of the liquid level threshold by 1.5m, do not add zinc ingots and the robot stops adding zinc ingots.

[0135] 6. Robot reset: The robot receives the instruction to stop adding zinc ingots, ends the adding work, and moves to the designated position to wait.

[0136] In the present invention, in the initial state, the steel wire is not subjected to stress, the baffle is attached to the slide body, and the passage of the zinc ingot in the blocking mechanism is closed. When the pressing plate is subjected to downward pressure, the steel wire is pulled, the baffle is lifted, and the passage of the zinc ingot in the blocking mechanism is opened, allowing the zinc ingot to slide down. After the zinc ingot slides down, the pressing plate is released, the steel wire returns to the initial state without stress, and the passage of the zinc ingot in the releasing mechanism is opened.

[0137] Example 7:

[0138] The process of the method of this embodiment is:

[0139] The inclination angle of the slide body when the zinc ingot automatically slides to the bottom of the slide body is calculated using the deadweight of the zinc ingot to be grasped and the rolling friction coefficient of the sliding body. The slide body is adjusted to the calculated inclination angle and the time t1 when the zinc ingot reaches the blocking mechanism is calculated.

[0140] The laser ranging liquid level sensor transmits the real-time data of the zinc pot liquid level to the robot's control unit within the set time interval.

[0141] The control unit compares the real-time data of the zinc pot liquid level with the set upper and lower limits of the liquid level threshold. If the real-time data of the zinc pot liquid level is greater than the upper limit of the liquid level threshold, it sends a command to the robot to replenish zinc ingots;

[0142] When the robot receives the instruction to replenish the zinc ingot, the control unit obtains the data of the visual monitoring component in real time to determine whether to grab the current zinc ingot. If the requirements are met, the zinc ingot is grabbed;

[0143] In the initial state, the blocking mechanism remains in a falling state, that is, in contact with the slide body, the passage of the zinc ingot in the blocking mechanism is closed, and the passage of the zinc ingot in the releasing mechanism is opened;

[0144] The robot places the grabbed zinc ingot on the slide body of the slide conveyor. The initial time t0 of the zinc ingot being placed on the slide body is recorded. After that, the zinc ingot automatically slides toward the zinc pot under its own gravity. The time is continuously recorded during this process. When the time pointer of the control unit reaches t0+t1, the zinc ingot reaches the end of the slide body and is prevented from entering the zinc pot by the blocking mechanism.

[0145] Set the drying time t3. When the time pointer of the control unit reaches t0+t1+t3, the zinc ingot is effectively dried at its current position using the residual heat of the zinc solution. When the drying is complete, the robot controls the release mechanism to lift the blocking mechanism, releasing the dried zinc ingot and allowing it to fall into the zinc pot.

[0146] After the zinc ingot falls into the zinc pot, the robot releases the release mechanism and returns to its initial state. The time is reset and the robot continues to determine whether zinc ingots need to be added. When the real-time zinc pot level data is below the lower level threshold, zinc ingots are no longer needed, the robot stops adding zinc ingots, and the robot resets. There is usually only one zinc ingot on the main slide. After the current zinc ingot falls into the zinc pot, the next zinc ingot is placed on the main slide.

[0147] The drying time is directly related to the specifications of the zinc ingots and can be set according to actual production needs. The average drying time of the zinc ingots is usually taken as a reference.

[0148] Example 8:

[0149] In this example, robot selection primarily considers factors such as the robot's rated load, working radius, repeatability, and environmental adaptability. The rated load must be ≥ 1.5 × the maximum weight of the zinc ingot, the working radius must be ≥ the maximum working diameter × 1.2, and the repeatability must be ≤ ±0.15 mm (at the ingot gripping position). Because the robot is located near the zinc pot, where temperatures can reach approximately 50°C, a high-temperature-resistant robot with a corrosion-resistant coating is required. For example, if the weight of a typical zinc ingot is ≤ 20 kg and the maximum motion diameter is approximately 1.5 m, a robot with a rated load of 50 kg, a reach (working radius) of 2 m, and repeatability of ≤ ±0.15 mm (at the ingot gripping position) can be selected.

[0150] The clamp in this embodiment is an adjustable high-temperature resistant clamp for grabbing zinc ingots of different specifications at high temperature. It can grab zinc ingots of different specifications under high temperature conditions, which is conducive to realizing the automation of the entire process from destacking and grabbing to unloading of zinc ingots.

[0151] The visual monitoring component can be equipped with lighting components such as LED light sources, adjustable light sources, etc. when necessary according to the working conditions. The 3D industrial camera of the visual monitoring component is placed at the end of the robot arm, and can also be placed at an appropriate position outside the robot through a mounting bracket according to the working conditions.

[0152] When destacking and grabbing, the zinc ingots are stacked in such a way that the first layer is placed with the convex and concave surfaces facing upwards, and from the second layer onwards, the flat surfaces are facing upwards (hereinafter defined as the convex and concave surfaces as the front side and the flat surfaces as the back side), or the front and back sides are stacked crosswise. The surface features of the front and back sides are quite different, resulting in inconsistent grabbing surfaces. The adapter fixture needs to be adjusted according to the front and back sides of the current zinc ingots.

[0153] Specifically, the visual monitoring component identifies the size, position and surface features (convex, concave and flat surfaces) of the zinc ingot, transmits the acquired information to the robot's control unit, determines whether the surface of the zinc ingot to be grasped is the front or back, and controls the vacuum suction cup at the corresponding position of the clamp to match the grasping position on the zinc ingot to be grasped, thereby driving the clamp to perform precise grasping.

[0154] The laser level sensor is placed directly above the zinc bath, approximately 1.5 meters from the surface, ensuring the emitted light is perpendicular to the surface. A protective shield ensures the sensor remains operational even in high-temperature environments.

[0155] The present invention can set the time for each part of the operation in the control unit according to actual production needs. In the galvanizing operation, the general robot operation area is about 2-3m away from the zinc pot, and there are many equipment arranged around the zinc pot. In the narrow and high-temperature space, the existing equipment cannot automatically load the material. The present invention does not need to set complex motors, sensors and other electronic control equipment on the slide body, and can automatically add zinc ingots. It has the advantages of high efficiency and automation, precise control of the sliding of zinc ingots, zinc ingot drying function, height adjustment, high temperature resistance and durability, simple and reliable structure, continuous operation capability, high safety, strong flexibility and adaptability, and easy operation. The robot grabs the zinc ingot and cooperates with the slide conveyor to realize fully automated addition. The blocking mechanism is combined to accurately control the stay and release of the zinc ingot, and the hot air flow above the zinc liquid is used to dry the zinc ingot, reducing safety hazards. The slide support structure can flexibly adjust the height to adapt to different working environments. The overall structure is simple and durable, suitable for large-scale continuous production, and significantly improves the efficiency and safety of the hot-dip galvanizing production line.

[0156] Example 9:

[0157] In order to solve the problem that the laser rangefinder is interfered by strong reflected light and dust on the surface of the zinc liquid during the measurement of the liquid level in the hot-dip galvanizing pot, the system of this embodiment also includes a nitrogen protection air curtain device. The nitrogen protection air curtain device is as follows: Figures 8-10 As shown, including:

[0158] a) a hollow nitrogen distribution pipe 71 having a diameter of approximately 10 mm, with multiple groups of small-hole nozzles 711 evenly distributed longitudinally on the pipe, each with a pore size of 0.5 mm; the nozzles of the small-hole nozzles are all directed toward the interior of the nitrogen distribution pipe;

[0159] b) a closed circular tube 72 having a diameter of approximately 50 mm, which is sleeved over the nitrogen distribution pipe and sealed at both ends of the closed circular tube except for the location of the nitrogen distribution pipe. An annular air inlet cavity surrounding the nitrogen distribution pipe is formed between the closed circular tube and the nitrogen distribution pipe; an air inlet port 721 is provided in the middle of the closed circular tube;

[0160] c) Nitrogen enters the annular cavity of the closed circular tube through the air inlet port 721, is evenly distributed longitudinally around the nitrogen distribution pipe through the cavity, and is then ejected inward by the small hole nozzle of the nitrogen distribution pipe to form a nitrogen protective air curtain along the height direction of the nitrogen distribution pipe;

[0161] d) The nitrogen protective air curtain device has an overall height of 150 mm and is suitable for protecting the optical path of a laser rangefinder.

[0162] The aperture of the small hole nozzles 711 is preferably 0.5 mm, and multiple groups of small hole nozzles 711 are evenly distributed along the height direction of the nitrogen distribution pipe, and each group has multiple small hole nozzles 711 evenly distributed along the circumference of the nitrogen distribution pipe.

[0163] The closed circular tube is made of high-temperature resistant stainless steel, and has a wall thickness of about 1 mm.

[0164] The air inlet port 721 is provided on the side wall of the closed circular tube to ensure that nitrogen enters the annular cavity evenly from the side.

[0165] The nitrogen protective air curtain device is fixed by a bracket directly below the lens of the laser ranging liquid level sensor, with the bottom 100 mm away from the surface of the zinc liquid (at this time, the zinc liquid is at the liquid level height without adding zinc ingots). The bracket is a structure that allows fine adjustment of the position and angle of the nitrogen distribution pipe. The upper end of the nitrogen protective air curtain device does not contact the laser ranging liquid level sensor. The bracket adjusts the inclination angle or position of the entire structure consisting of the nitrogen distribution pipe and the closed circular tube to ensure that the laser can pass through the hollow structure of the nitrogen distribution pipe to adapt to different rangefinder models and on-site working conditions, so that the nitrogen protective air curtain inside the nitrogen distribution pipe evenly covers the target ranging laser channel.

[0166] Example 10:

[0167] The system of this embodiment further includes a cloud, which includes a cloud server, a cloud database, a statistical module, and a time series prediction model. The process of the hot-dip galvanizing method is:

[0168] 1. Data Collection

[0169] A laser ranging level sensor measures the zinc pot's liquid level in real time and transmits this information to the robot's control unit. Based on the upper and lower level thresholds, the robot's control unit determines whether zinc ingots need to be added, executes the appropriate action, and simultaneously uploads the liquid level and judgment results to the cloud.

[0170] At the request of the robot's control unit, the visual monitoring component takes pictures of the zinc pile. The images and recognition results are uploaded to the cloud through the robot's control unit, and the operation time and grasping status are associated.

[0171] The robot's control unit records the zinc ingot adding action (location, time, quantity) in detail and uploads it to the cloud to form a complete operation log.

[0172] 2. Secure data transmission

[0173] The robot's control unit uses a transmission module to transmit key production data collected in real time to a cloud server via a secure network protocol (TCP / IP). The transmission module supports breakpoint resumption and retry mechanisms to ensure data integrity and real-time performance.

[0174] 3. Cloud data storage and management

[0175] A distributed cloud database is established, including a liquid level data table, a zinc ingot usage log table, and a visual image information table.

[0176] The liquid level data table stores timestamps and real-time liquid level values, and the zinc ingot usage log table records the amount of zinc ingots added each time and the corresponding time, supporting fast aggregate queries.

[0177] 4. Zinc usage statistics and time series forecast:

[0178] The statistics module automatically summarizes zinc usage daily, supports real-time query of the cumulative zinc usage for the current hour, day, and month, and allows users to customize query and export within any time period.

[0179] Combined with time series prediction models (such as ARIMA, LSTM and other deep learning models), based on historical zinc usage data, future zinc ingot consumption trends are predicted to assist in formulating scientific and reasonable material procurement and production plans.

[0180] 5. Remote access and interface:

[0181] It has a user access interface based on browser and mobile APP, supporting multi-terminal and multi-user login.

[0182] The interface provides intuitive data display, including real-time liquid level monitoring, zinc usage statistics, historical data query interface and forecast trend curve.

[0183] Users can query and view statistical reports by time period and export data in formats such as xlsx.

[0184] The drawings of the disclosed embodiments of the present invention only involve the core innovative aspects of the present invention. The subsequent hot-dip galvanizing process can be implemented with reference to the prior art. In the absence of conflict, the same embodiment and different embodiments of the present invention can be combined with each other.

[0185] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

[0186] Any matters not described in the present invention are applicable to the prior art.

Claims

1. An automatic zinc ingot adding system for hot-dip galvanizing, comprising a robot for gripping the zinc ingots, a slideway conveyor for transporting the zinc ingots, a visual monitoring component, and a laser ranging level sensor installed in the zinc pot for monitoring the zinc pot liquid level, characterized in that: The slide conveying device includes a slide body, a blocking mechanism and a releasing mechanism; The slide body is made of high-temperature resistant material, with one side close to the robot operating area and the other side extending above the zinc liquid in the zinc pot; the zinc ingot automatically slides to the end of the slide body under the action of its own gravity on the slide body; the slide body is provided with multiple rollers; The blocking mechanism is located at the end of the slide body and is used to temporarily block the zinc ingot above the zinc liquid in the zinc pot for drying; The release mechanism is linked with the blocking mechanism, and is used for releasing the zinc ingot by the robot after the zinc ingot is dried; The laser ranging liquid level sensor is linked to the robot for control. The laser ranging liquid level sensor transmits real-time data of the zinc pot liquid level to the robot's control unit within a set time interval. The control unit determines whether to trigger the instruction to replenish zinc ingots based on the set upper and lower limits of the liquid level. The visual monitoring component is used to identify the position, direction and surface condition of zinc ingots in the zinc pile; The control unit is electrically connected to the visual monitoring component and determines whether the robot grabs the monitored zinc ingot according to the detection result of the visual monitoring component; The blocking mechanism includes a small support frame, a baffle, a pulley and a rotating screw component; the small support frame is made of high-temperature resistant stainless steel material, has an N-shaped structure, and is fixedly connected to the slide main body through the bottom of the small support frame; two pulleys are symmetrically installed on the upper end of the small support frame to reduce the friction resistance of the steel wire; the small support frame is provided with a rotatable rotating screw component in the middle part in the vertical direction, and the rotating screw component is composed of a screw, a screw bearing and a screw cover plate, the screw cover plate half covers the screw bearing and the screw, the upper end of the screw cover plate extends toward the zinc pot and is fixedly connected to the baffle, one end of the baffle plate is connected to the screw cover plate, and the other end is connected to a steel plate of equal width in the vertical direction; the lower end of the steel plate is used to block the zinc ingot, and the upper end has a through hole for connecting the steel wire, and the through hole is consistent with the two pulleys in the horizontal direction; When the baffle is in a powerless state, it temporarily blocks the zinc ingot at the end of the slide by its own gravity, causing it to stay above the zinc pot for a period of time, and the hot air flow above the zinc liquid is used to dry the zinc ingot; The pulley on the small support frame is connected to the through hole on the baffle and the release mechanism through a steel wire. In the initial state, the lower part of the baffle is attached to the slide body, and the passage of the zinc ingot in the blocking mechanism is closed. The release mechanism also includes a small support frame, a pulley installed on the small support frame, and a rotating screw component installed in the middle of the small support frame, and also includes a pressing plate and a pressing plate connecting piece; The small support frame of the release mechanism has the same structure as the small support frame of the blocking mechanism, and maintains the same height and parallel configuration; the lower end of the small support frame of the release mechanism is fixedly connected to the slide body, and two pulleys are symmetrically installed on the upper end; The upper portion of the screw cover plate in the rotating screw component of the release mechanism is fixed to the press plate connecting piece, which extends toward the robot operating area and is symmetrically provided with steel wire holes for guidance. The press plate connecting piece is fixedly connected to the press plate; one end of the two steel wires is fixed to the steel wire holes on the press plate connecting piece, and the other end passes through two pulleys along the length direction of the slide body and is fixed to the through-holes on the baffle, thereby ensuring stable connection and guidance of the steel wires; The pressing plate is made of high-temperature resistant stainless steel. The robot presses the pressing plate to raise and lower the baffle of the blocking mechanism, thereby controlling the retention and release of the zinc ingot. The slide conveyor device relies on the height difference to make the zinc ingot automatically slide to the blocking mechanism. The zinc ingot stays above the zinc pot and dries, ensuring that the zinc ingot is fully dehydrated before entering the zinc pot. The blocking mechanism and the release mechanism are linked by a steel wire. When the release mechanism loosens or tightens the steel wire, the baffle of the blocking mechanism can be dropped or lifted. The robot controls the loosening or tightening of the steel wire connecting the release mechanism and the blocking mechanism through the execution component, thereby controlling the blocking mechanism to drop or lift to achieve blocking or releasing the zinc ingot.

2. The automatic zinc ingot adding system for hot dip galvanizing according to claim 1, characterized in that: The front and rear ends of the slide body are supported by the slide support structure, which includes a front-end support structure close to the robot operating area, a rear-end support structure close to the zinc pot, and a fixed bracket. The front-end support structure and the rear-end support structure have the same structure but different heights, forming a height difference, which makes the slide body appear sloped; the end of the slide body facing the zinc pot is lower than the end facing the robot operating area, and the zinc ingot automatically slides to the end of the slide body through the rollers.

3. The automatic zinc ingot adding system for hot dip galvanizing according to claim 2, characterized in that: The height difference between the front and rear end support structures can be adjusted freely.

4. The automatic zinc ingot adding system for hot dip galvanizing according to claim 1, characterized in that: The system also includes a nitrogen protective air curtain device, which is fixed to the bottom of the lens of the laser ranging liquid level sensor through a bracket. The nitrogen protective air curtain device includes a hollow nitrogen distribution pipe and a closed circular tube. The closed circular tube is sleeved on the outside of the nitrogen distribution pipe, and the area between the nitrogen distribution pipe and the closed circular tube is sealed at both ends, forming an annular air inlet cavity between the nitrogen distribution pipe and the closed circular tube. An air inlet interface is provided in the middle of the closed circular tube; A plurality of groups of small-hole nozzles with nozzles facing the interior of the nitrogen distribution pipe are arranged in the height direction of the nitrogen distribution pipe, and a plurality of small-hole nozzles are evenly arranged in each group along the circumference of the nitrogen distribution pipe.

5. The automatic zinc ingot adding system for hot dip galvanizing according to claim 4, characterized in that: The bracket is a structure that allows the position and angle of the nitrogen distribution pipe to be fine-tuned.

6. The automatic zinc ingot adding system for hot dip galvanizing according to claim 1, characterized in that: The system further includes a cloud, which includes a cloud server, a user access interface, a cloud database, a statistical module, and a time series prediction model; The cloud database contains a liquid level data table, a zinc ingot usage log table, and a visual image information table; The liquid level data table stores the timestamp and real-time liquid level value, and the zinc ingot usage log table records the amount of zinc ingot added each time and the corresponding time; The statistics module is used to automatically summarize zinc usage; The time series forecasting model is used to predict future zinc ingot consumption trends based on historical zinc consumption data; Communicate with terminals or users through the user access interface.

7. A method for automatically adding zinc ingots for hot-dip galvanizing, characterized in that: The method uses the automatic zinc ingot adding system for hot-dip galvanizing according to any one of claims 1 to 6, comprising the following steps: The inclination angle of the slide body when the zinc ingot automatically slides to the bottom of the slide body is calculated using the deadweight of the zinc ingot to be grasped and the rolling friction coefficient of the sliding body. The slide body is adjusted to the calculated inclination angle and the time t1 when the zinc ingot reaches the blocking mechanism is calculated. The laser ranging liquid level sensor transmits the real-time data of the zinc pot liquid level to the robot's control unit within the set time interval. The control unit compares the real-time data of the zinc pot liquid level with the set upper and lower limits of the liquid level threshold. If the real-time data of the zinc pot liquid level is greater than the upper limit of the liquid level threshold, it sends a command to the robot to replenish zinc ingots; When the robot receives the instruction to replenish the zinc ingot, the control unit obtains the data of the visual monitoring component in real time to determine whether to grab the current zinc ingot. If the requirements are met, the zinc ingot is grabbed; In the initial state, the blocking mechanism remains in the falling state, the passage of the zinc ingot in the blocking mechanism is closed, and the passage of the zinc ingot in the releasing mechanism is opened; The robot places the grabbed zinc ingot on the slide body of the slide conveyor. The initial time t0 of the zinc ingot being placed on the slide body is recorded. After that, the zinc ingot automatically slides toward the zinc pot under its own gravity. The time is continuously recorded during this process. When the time pointer of the control unit reaches t0+t1, the zinc ingot reaches the end of the slide body and is prevented from entering the zinc pot by the blocking mechanism. Set the drying time t3. When the time pointer of the control unit reaches t0+t1+t3, the zinc ingot is effectively dried at its current position by utilizing the residual heat of the zinc liquid. When the drying is completed, the robot controls the release mechanism to lift the blocking mechanism and release the dried zinc ingot. After the zinc ingot falls into the zinc pot, the robot releases the release mechanism and returns to the initial state. The time is reset and it continues to determine whether the zinc ingot needs to be added. When the real-time data of the zinc pot liquid level is lower than the lower limit of the liquid level threshold, the robot stops adding zinc ingots and resets.

Images