Automatic thermal zinc spraying device

Abstract

The invention discloses an automatic hot zinc spraying device, which relates to the technical field of metal surface treatment, and has the technical key points that a base is used as a basis, three groups of zinc spraying gun groups which are annularly and uniformly distributed are arranged, and all-directional accurate positioning of a spraying gun is realized through an axial and radial adjusting assembly and an axial angle fine adjusting assembly, so that the zinc spraying uniformity is ensured; the driving mechanism adopts a servo motor and a clamping assembly, and can flexibly clamp the outer wall or the inner wall of the pipe blank and drive the pipe blank to rotate, so that the zinc spraying efficiency is improved; the device is provided with a defect compensation mechanism, the multispectral analyzer scans the surface of the tube blank in real time, and the residual or impurity area of the oxide layer is accurately recognized through a machine learning algorithm; once defects are found, the control chip immediately triggers the auxiliary spray gun set to conduct local supplementary spraying, galvanic corrosion caused by a zinc-free area is effectively avoided, and the zinc spraying quality is remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of metal surface treatment, and in particular to an automatic hot zinc spraying device. Background Art

[0002] In modern industrial production, the surface processing technology of alloy pipes plays a crucial role in enhancing the corrosion resistance of materials, extending the service life, and meeting the usage requirements under specific environments. As a key technical equipment in the field of alloy pipe surface processing, the application and development of the automatic hot zinc spraying device have greatly promoted the progress of surface treatment processes.

[0003] The surface processing of alloy pipes encompasses a series of process methods aimed at improving the surface properties of alloy pipes, including but not limited to machining, chemical treatment, electroplating, and thermal spraying, etc. Among them, thermal spraying technology has been widely used in the field of alloy pipe surface protection due to its ability to form a coating with high adhesion strength, density, and corrosion resistance. The thermal spraying process forms a coating with specific functions by spraying molten or semi-molten spraying materials (such as metals, alloys, ceramics, etc.) at high speed onto the surface of the pretreated substrate, thereby endowing the alloy pipe with excellent wear resistance, corrosion resistance, high temperature resistance, etc.

[0004] The automatic hot zinc spraying device is a specific application embodiment of thermal spraying technology in the zinc layer protection of alloy pipes. In the traditional zinc spraying process for aluminum pipes, the surface treatment is generally carried out by the two-point zinc spraying method. However, this process has many technical defects: Since two-point zinc spraying is adopted, the spraying material can only be sprayed onto the surface of the aluminum pipe from two specific positions, resulting in a significant difference in the thickness of the zinc layer in the circumferential direction of the aluminum pipe. The zinc layer is thicker in the area near the spraying point, while it is relatively thinner in the area far from the spraying point, and even an effective zinc layer coverage may not be formed. The uneven distribution of the zinc layer in the circumferential direction causes zinc-free areas on the surface of the aluminum pipe. In harsh environments such as humid and corrosive media, an electric couple cell will be formed between the aluminum pipe substrate and the zinc layer. Due to the different electrode potentials of aluminum and zinc, aluminum will preferentially corrode as the anode, thus accelerating the damage of the aluminum pipe and seriously affecting the service life and safety of the aluminum pipe. Summary of the Invention

[0005] In order to solve the above technical problems, the purpose of the present invention is to provide an automatic hot zinc spraying device to improve the zinc spraying uniformity and avoid the galvanic corrosion caused by zinc-free areas.

[0006] To achieve the above purpose, the present invention provides the following technical solutions:

[0007] An automatic hot zinc spraying device, comprising:

[0008] A base, serving as the foundation of the device;

[0009] Three groups of annularly evenly distributed zinc spraying gun groups are movably connected to the base through an axial position adjusting component. A radial adjusting component is arranged between each group of the zinc spraying gun groups and the axial position adjusting component for adjusting the distance between the spraying gun and the surface of the tube blank; an axial angle fine-tuning component is arranged between the zinc spraying gun group and the radial adjusting component;

[0010] A driving mechanism for driving the rotation of the tube blank includes a servo motor fixedly connected to the base. A clamping component is fixedly arranged on the output shaft of the servo motor, and the clamping component is used for clamping and locking the outer wall or inner wall of the tube blank;

[0011] A defect compensation mechanism is arranged on the axial position adjusting component and includes a control chip, a multispectral analyzer and an auxiliary spraying gun group; the multispectral analyzer scans the surface topography of the tube blank in real time, identifies the residual oxide layer or impurity area through a machine learning algorithm, triggers the auxiliary spraying gun group to perform local supplementary spraying through the control chip, and the auxiliary spraying gun group is connected to the axial position adjusting component through the radial adjusting component;

[0012] When the multispectral analyzer identifies a defect and the machine learning model outputs the defect coordinates, the control chip calculates the spraying time window of the auxiliary spraying gun according to the rotation speed of the tube blank, and the rotation speed of the tube blank is obtained by the feedback of the encoder of the servo motor; then, the control chip maps the defect area and defect depth output by the machine learning model into zinc flow rate (Q = K_p×S_defect, S_defect is the defect area) through the PID algorithm, and controls the radial movement compensation distance of the auxiliary spraying gun group (Δd = 0.2×defect depth).

[0013] Preferably, the axial position adjusting component includes two parallel translation slides connected to the base. The translation slides are parallel to the axis of the tube blank. The movable parts of the two translation slides are fixedly connected to form an annular movable frame. The number of radial adjusting components arranged on the movable frame is four, corresponding to three groups of the zinc spraying gun groups and one group of the auxiliary gun groups respectively.

[0014] Preferably, the radial adjusting component is set as a telescopic electric cylinder arranged in the radial direction of the tube blank, and its fixed part is fixedly connected to the movable frame. The axial angle adjusting component is set as an electric turntable fixedly connected to the movable part of the telescopic electric cylinder, and the movable part of the electric turntable is fixedly connected to the zinc spraying gun group. The electric turntable is used for adjusting the included angle between the axis of the zinc spraying gun group and the axis of the tube blank.

[0015] Preferably, the clamping component includes a rotating frame fixedly connected to the output shaft of the servo motor. Clamping electric cylinders are fixedly arranged annularly and evenly on the rotating frame. The movable part of the clamping electric cylinder facing the center of the rotating frame is provided with a clamping arc plate, and the contact surface of the clamping arc plate with the tube blank is sprayed with a wear-resistant coating.

[0016] Preferably, the steps of machine learning of the multispectral analyzer are as follows:

[0017] Step 1, multimodal data fusion: Collect spectral reflectance and surface topography images through a multispectral analyzer, and fuse the spectral features of the oxide layer-specific reflectance with the image features of impurity morphology and texture;

[0018] Step 2, improve the object detection model: Use the YOLOv3 model optimized by the Xception backbone network, combined with transfer learning, and the pre-training dataset is the industrial metal surface defect library;

[0019] Step 3, dynamic compensation decision-making: Based on the defect coordinates, area, and depth obtained by real-time detection combined with machine learning, dynamically adjust the parameters of the injection time window, radial position, and zinc flow rate of the auxiliary spray gun through the PID control algorithm.

[0020] Preferably, the translation slide is a ball screw type slide, and the movable frame is a ring-shaped aluminum alloy frame.

[0021] Preferably, a pressure sensor is provided between the clamping electric cylinder and the clamping arc plate, and the pressure sensor is interlocked with the servo motor; when the clamping force reaches the set threshold, the servo motor is triggered to unlock and start.

[0022] Preferably, in step 1, the weighted fusion algorithm is used for the fusion of spectral and image data, the spectral feature weight coefficient α = 0.7, and the image feature weight coefficient β = 0.3; in step 2, the freezing ratio of the pre-training parameters of transfer learning is 60% for the convolutional layer and 40% for the fully connected layer, and the batch size is set to 32.

[0023] Preferably, the nozzles of the auxiliary spray gun group are detachable tungsten steel nozzles, and there are three options for the outlet aperture: 2mm, 3mm, and 5mm; a preheating chamber is provided between the nozzles of the auxiliary gun group and the powder supply pipe of the auxiliary gun group, and a spiral resistance wire is arranged in the preheating chamber, and the temperature of the resistance wire is maintained at 380 ± 5 °C by a PID controller.

[0024] The present invention has the following beneficial effects:

[0025] I. The coordinated action of multiple sets of zinc spraying guns and adjustment components: The automatic hot zinc spraying device is equipped with three sets of zinc spraying gun groups evenly distributed in a ring. They are movably connected to the base through the axial position adjustment components, and a radial adjustment component is configured between each set of zinc spraying gun groups and the axial position adjustment components to adjust the distance between the spray gun and the surface of the tube blank. An axial angle fine-tuning component is also configured between the zinc spraying gun group and the radial adjustment component. This design of multiple sets of zinc spraying gun groups with a variety of adjustment components enables the spray gun to be flexibly adjusted in different directions and distances, allowing for all-round and multi-angle zinc spraying operations on the surface of the tube blank, effectively avoiding local uneven zinc spraying that may be caused by a single zinc spraying method, and thus significantly improving the uniformity of zinc spraying.

[0026] II. Translation slide and movable frame structure: The axial position adjustment component includes two parallel translation slides connected to the base. The translation slides are parallel to the axis of the tube blank. The movable parts of the two translation slides are jointly and fixedly connected to an annular movable frame. There are four radial adjustment components arranged on the movable frame, corresponding to three sets of zinc spraying gun groups and one set of auxiliary gun groups respectively. This structure enables the zinc spraying gun groups and the auxiliary gun groups to move smoothly along the axis of the tube blank, further expanding the zinc spraying range and ensuring uniform zinc layer coverage on the tube blank in both the axial and circumferential directions.

[0027] III. Axial angle fine-tuning component: The radial adjustment component is set as a telescopic electric cylinder arranged radially on the tube blank. Its fixed part is fixedly connected to the movable frame. The axial angle adjustment component is set as an electric turntable fixedly connected to the movable part of the telescopic electric cylinder. The movable part of the electric turntable is fixedly connected to the zinc spraying gun group and is used to adjust the angle between the axis of the zinc spraying gun group and the axis of the tube blank. Through the precise adjustment of the electric turntable, the spraying angle of the zinc spraying gun group can be flexibly adjusted according to the shape of the tube blank and the zinc spraying requirements, enabling the zinc powder to be sprayed onto the surface of the tube blank at the best angle and improving the uniformity of zinc powder adhesion.

[0028] IV. Defect compensation mechanism: The device is provided with a defect compensation mechanism, which is arranged on the axial position adjustment component and includes a control chip, a multispectral analyzer, and an auxiliary spray gun group. The multispectral analyzer scans the surface topography of the tube blank in real time, identifies the areas with residual oxide layers or impurities through machine learning algorithms, and triggers the auxiliary spray gun group to perform local supplementary spraying through the control chip. This real-time monitoring and local supplementary spraying mechanism can promptly detect and process the defective areas on the surface of the tube blank, avoiding the problem of galvanic corrosion caused by the absence of zinc in the defective areas.

[0029] V. Precise defect identification and compensation calculation: When the multispectral analyzer identifies a defect, after the machine learning model outputs the defect coordinates, the control chip calculates the injection time window of the auxiliary spray gun according to the rotation speed of the tube blank, and the rotation speed of the tube blank is obtained from the encoder feedback of the servo motor. Then, the control chip maps the defect area and defect depth output by the machine learning model into zinc flow rate (Q = K_p × S_defect, where S_defect is the defect area) through the PID algorithm, and controls the radial movement compensation distance of the auxiliary spray gun group (Δd = 0.2 × defect depth). This precise calculation and control method ensure that the auxiliary spray gun group can accurately re-spray the defect area, enabling the defect area to obtain sufficient zinc layer coverage and effectively preventing the occurrence of galvanic corrosion.

[0030] VI. Combination of multispectral analysis and machine learning: The machine learning steps of the multispectral analyzer include multimodal data fusion, improved object detection model, and dynamic compensation decision-making. By fusing the spectral features of the specific reflectivity of the oxide layer with the image features of the impurity morphology and texture, and using the YOLOv3 model optimized by the Xception backbone network combined with transfer learning, with the pre-trained dataset being the industrial metal surface defect library, it can more accurately identify the defects on the surface of the tube blank. Based on the defect coordinates, area, and depth obtained through real-time detection combined with machine learning, the PID control algorithm is used to dynamically adjust the parameters of the injection time window, radial position, and zinc flow rate of the auxiliary spray gun, further improving the accuracy and effectiveness of defect compensation, thereby effectively avoiding galvanic corrosion caused by zinc-free areas.

[0031] VII. Optimized design of the auxiliary spray gun group: The nozzles of the auxiliary spray gun group adopt detachable tungsten steel nozzles, and there are three optional outlet apertures of 2mm, 3mm, and 5mm, which can select the appropriate nozzle according to the size and shape of the defect to improve the re-spraying effect. A preheating chamber is provided between the nozzles of the auxiliary gun group and the powder supply pipe of the auxiliary gun group. The preheating chamber is internally provided with spiral resistance wires, and the temperature of the resistance wires is maintained at 380 ± 5 °C by a PID controller, so that the zinc powder is fully preheated before spraying, improving the fluidity and adhesion of the zinc powder, ensuring the zinc layer quality of the re-sprayed area, and further reducing the risk of galvanic corrosion. Description of the Drawings

[0032] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention, and therefore should not be regarded as limiting the scope. For those of ordinary skill in the art, other related drawings can be obtained based on these drawings without creative efforts.

[0033] Figure 1 It is the front view of the first embodiment of the present invention.

[0034] Figure 2 Side view (excluding the clamping assembly) of the first embodiment of the present invention.

[0035] Figure 3 Side view of the clamping assembly of the first embodiment of the present invention.

[0036] Figure 4 Cross-sectional view of the preheating chamber of the auxiliary gun group of the second embodiment of the present invention.

[0037] In the figure: 1, base; 2, zinc spraying gun group; 301, servo motor; 321, rotating frame; 322, clamping electric cylinder; 323, clamping arc plate; 324, pressure sensor; 401, multispectral analyzer; 402, auxiliary spray gun group; 421, tungsten steel nozzle; 422, preheating chamber; 423, resistance wire; 424, PID controller; 403, control chip; 511, translation sliding table; 512, movable frame; 521, telescopic electric cylinder; 531, electric turntable. Specific embodiments

[0038] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative efforts shall fall within the protection scope of the present invention.

[0039] The first embodiment

[0040] As Figures 1 to 3As shown in the figure, an automatic hot zinc spraying device includes: a base 1, which serves as the foundation of the device; a group of annularly and evenly distributed zinc spraying gun groups 2, which are movably connected to the base 1 through an axial position adjusting component. A radial adjusting component is arranged between each zinc spraying gun group 2 and the axial position adjusting component, which is used to adjust the distance between the spraying gun and the surface of the tube blank; an axial angle fine-tuning component is arranged between the zinc spraying gun group 2 and the radial adjusting component; a driving mechanism for driving the rotation of the tube blank, which includes a servo motor 301 fixedly connected to the base 1, and a clamping component is fixedly arranged on the output shaft of the servo motor 301, and the clamping component is used to clamp and lock the outer wall or inner wall of the tube blank; a defect compensation mechanism is arranged on the axial position adjusting component, which includes a control chip 403, a multi-spectral analyzer 401 and an auxiliary spraying gun group 402; the multi-spectral analyzer 401 scans the surface topography of the tube blank in real time, identifies the residual oxide layer or impurity area through a machine learning algorithm, triggers the auxiliary spraying gun group 402 to perform local supplementary spraying through the control chip 403, and the auxiliary spraying gun group 402 is connected to the axial position adjusting component through the radial adjusting component; when the multi-spectral analyzer 401 identifies a defect, after the machine learning model outputs the defect coordinates, the control chip 403 calculates the spraying time window of the auxiliary spraying gun according to the rotation speed of the tube blank, and the rotation speed of the tube blank is obtained by the feedback of the encoder of the servo motor 301; then, the control chip 403 maps the defect area and defect depth output by the machine learning model into zinc flow rate (Q = K_p × S_defect, S_defect is the defect area) through a PID algorithm, and controls the radial movement compensation distance of the auxiliary spraying gun group 402 (Δd = 0.2 × defect depth).

[0041] As Figures 1 to 3As shown in the figure, the automatic hot zinc spraying device realizes uniform and high-quality zinc spraying on the surface of the tube blank through the coordinated work of each component, and precisely compensates the defective area through the defect compensation mechanism to avoid galvanic corrosion caused by defects. The three groups of annularly distributed zinc spraying gun groups 2 are movably connected to the base 1 by means of the axial position adjustment component and can move along the axial direction of the tube blank; the radial adjustment component can adjust the distance between the spray gun and the surface of the tube blank; the axial angle fine adjustment component can adjust the included angle between the axis of the zinc spraying gun group 2 and the axis of the tube blank. These adjustment functions enable the zinc spraying gun group 2 to perform all-round and multi-angle zinc spraying on the surface of the tube blank from different directions and distances according to the shape of the tube blank and the zinc spraying requirements, ensuring the uniformity of zinc spraying. After adjusting the position and angle, the zinc spraying gun group 2 sprays zinc powder on the rotating surface of the tube blank to realize the zinc spraying operation. The servo motor 301 fixedly connected to the base 1 serves as a power source, and the clamping component on its output shaft can clamp and lock the outer wall or inner wall of the tube blank. The servo motor 301 drives the clamping component to rotate, and then drives the tube blank to rotate, so that the surface of the tube blank can evenly receive the zinc powder sprayed by the zinc spraying gun group 2, improving the zinc spraying efficiency and uniformity. The encoder of the servo motor 301 can real-time feedback the rotation speed of the tube blank, providing data support for the subsequent defect compensation mechanism to calculate the spraying time window of the auxiliary spray gun. The multi-spectral analyzer 401 scans the surface topography of the tube blank in real time, analyzes the scanned data through machine learning algorithms, and identifies defects such as residual oxide layers or impurity areas. The machine learning algorithm fuses multi-modal data and adopts an improved object detection model to more accurately identify defects. When the multi-spectral analyzer 401 identifies a defect, it transmits information such as the defect coordinates to the control chip 403, and the control chip 403 triggers the auxiliary spray gun group 402 to perform local supplementary spraying. The auxiliary spray gun group 402 is connected to the axial position adjustment component through the radial adjustment component and can flexibly adjust the position to align with the defective area. The control chip 403 calculates the spraying time window of the auxiliary spray gun according to the rotation speed of the tube blank to ensure that supplementary spraying is carried out when the tube blank rotates to the appropriate position. At the same time, the defect area and depth output by the machine learning model are mapped to the zinc flow rate through the PID algorithm (Q = K_p × S_defect, S_defect is the defect area), and the radial movement compensation distance of the auxiliary spray gun group 402 is controlled (Δd = 0.2 × defect depth) to achieve precise supplementary spraying of the defective area and avoid galvanic corrosion caused by the absence of zinc in the defective area.

[0042] As Figures 1 to 3As shown in the figure, the axial position adjustment assembly includes two parallel translation sliders 511 connected to the base 1. The translation sliders 511 are parallel to the axis of the tube blank. The movable parts of the two translation sliders 511 are fixedly connected to an annular movable frame 512. The number of radial adjustment assemblies provided on the movable frame 512 is four, corresponding to three groups of zinc spraying gun groups 2 and one group of auxiliary gun groups respectively. By moving the movable parts of the translation sliders 511, the annular movable frame 512 is driven to move along the axis of the tube blank. Furthermore, the radial adjustment assemblies, axial angle adjustment assemblies, and the connected zinc spraying gun groups 2 and auxiliary gun groups provided on the movable frame 512 are integrally moved along the axis of the tube blank, realizing the adjustment of the axial positions of the zinc spraying gun groups 2 and the auxiliary gun groups to meet the zinc spraying requirements of tube blanks of different lengths, or performing zinc spraying operations at different axial positions of the tube blank according to the requirements of the zinc spraying process.

[0043] As Figures 1 to 3 As shown in the figure, the radial adjustment assembly is set as a telescopic electric cylinder 521 arranged radially with respect to the tube blank. Its fixed part is fixedly connected to the movable frame 512. The movable part of the telescopic electric cylinder 521 can perform telescopic movement, driving the zinc spraying gun groups 2 and the auxiliary gun groups connected to the movable part through subsequent components to move radially with respect to the tube blank, thereby adjusting the distance between the spray gun and the surface of the tube blank. According to the diameter of the tube blank or the requirements of the zinc spraying process, the appropriate distance between the spray gun and the surface of the tube blank is adjusted to ensure the uniformity and quality of zinc spraying. The axial angle adjustment assembly is set as an electric turntable 531 fixedly connected to the movable part of the telescopic electric cylinder. The movable part of the electric turntable 531 is fixedly connected to the zinc spraying gun group 2. The electric turntable 531 is used to adjust the angle between the axis of the zinc spraying gun group 2 and the axis of the tube blank. The electric turntable 531 can rotate around its central axis. By rotating the movable part of the electric turntable 531, the zinc spraying gun group 2 is driven to rotate, thereby adjusting the angle between the axis of the zinc spraying gun group 2 and the axis of the tube blank. According to the shape of the tube blank and the requirements of zinc spraying, the spraying angle of the zinc spraying gun group 2 is adjusted so that the zinc powder can be sprayed onto the surface of the tube blank at an appropriate angle, further improving the uniformity and quality of zinc spraying. For the auxiliary gun group, its spraying angle is also adjusted through the axial angle adjustment assembly to more accurately perform supplementary spraying on the defective area.

[0044] As Figures 1 to 3As shown in the figure, the clamping assembly includes a rotating frame 321 fixedly connected to the output shaft of the servo motor 301. Clamping cylinders 322 are fixedly arranged in a circumferential and evenly distributed manner on the rotating frame 321. A clamping arc plate 323 is arranged on the movable part of the clamping cylinder 322 facing the center of the rotating frame 321. A wear-resistant coating is sprayed on the contact surface between the clamping arc plate 323 and the tube blank. When it is necessary to clamp the tube blank, the movable part of the clamping cylinder 322 drives the clamping arc plate 323 to move towards the center of the rotating frame 321. Multiple clamping arc plates 323 cooperate to clamp and lock the tube blank. Since the clamping arc plates 323 are circumferentially and evenly distributed on the rotating frame 321, they can adapt to tube blanks of different diameters, and stable clamping of tube blanks of different sizes can be achieved by adjusting the telescopic amount of the clamping cylinder 322. The wear-resistant coating can reduce the wear when the clamping arc plate 323 contacts the tube blank, extend the service life of the clamping assembly, and ensure the stability and reliability of clamping. Driven by the servo motor 301, the rotating frame 321 drives the clamped tube blank to rotate, providing power for subsequent zinc spraying operations.

[0045] As Figures 1 to 3 shown, the steps of machine learning of the multispectral analyzer 401 are as follows:

[0046] Step 1, multimodal data fusion: The multispectral analyzer 401 is used to collect spectral reflectance and surface topography images, and fuse the spectral features of the specific reflectance of the oxide layer with the image features of the impurity morphology and texture; the spectral features of the specific reflectance of the oxide layer are fused with the image features of the impurity morphology and texture. Through this fusion, the data information of two different modalities, namely spectrum and image, can be comprehensively utilized to more comprehensively and accurately describe the defect features on the surface of the tube blank, providing a richer data basis for subsequent object detection and improving the accuracy of defect recognition.

[0047] Step 2, improve the object detection model: Use the YOLOv3 model optimized by the Xception backbone network. The Xception network has efficient feature extraction capabilities and can better capture the feature information in the image. Combining transfer learning and using the industrial metal surface defect library as a pre-training data set enables the model to have a certain defect recognition ability at the initial stage of training, accelerating the convergence speed of the model and improving the generalization performance of the model. This improved object detection model can more accurately and quickly identify defects such as oxide layer residues and impurities on the surface of the tube blank, providing accurate defect information for subsequent defect compensation.

[0048] Step 3, Dynamic Compensation Decision: Based on the defect coordinates, area, and depth obtained through real-time detection combined with machine learning, parameters such as the spraying time window, radial position, and zinc flow rate of the auxiliary spray gun are dynamically adjusted through the PID control algorithm. According to the defect coordinates, calculate the spraying time window of the auxiliary spray gun to ensure supplementary spraying when the tube blank rotates to the appropriate position; according to the defect area and depth, map the defect area to the zinc flow rate through the PID algorithm (Q = K_p × S_defect, where S_defect is the defect area), and map the defect depth to the radial movement compensation distance of the auxiliary spray gun (Δd = 0.2 × defect depth), realizing precise supplementary spraying of the defect area, avoiding galvanic corrosion caused by the absence of zinc in the defect area, and improving the quality of zinc spraying.

[0049] As Figures 1 to 3 shown, the translation slide 511 is a ball screw type slide, and the movable frame 512 is set as an annular aluminum alloy frame. The ball screw type slide is used, and based on the transmission principle of the ball screw, the rotational motion of the motor is converted into a linear motion, featuring high precision, high rigidity, and high efficiency. The movable frame 512 is set as an annular aluminum alloy frame. The aluminum alloy material has the advantages of light weight, high strength, and corrosion resistance, which not only reduces the overall weight of the device but also ensures the stability and durability of the frame. The translation slide 511 drives the annular aluminum alloy frame to move along the axial direction of the tube blank, realizing the adjustment of the axial position of the zinc spraying gun group 2 and the auxiliary gun group on the tube blank, meeting the zinc spraying requirements of tube blanks with different lengths or the zinc spraying process requirements at different axial positions.

[0050] As Figures 1 to 3 shown, a pressure sensor 324 is provided between the clamping electric cylinder 322 and the clamping arc plate 323, and the pressure sensor 324 is interlocked with the servo motor 301; when the clamping force reaches the set threshold, the servo motor 301 is triggered to unlock and start. A pressure sensor 324 is provided between the clamping electric cylinder 322 and the clamping arc plate 323, and the pressure sensor 324 monitors the magnitude of the clamping force in real time. When the clamping force reaches the set threshold, the pressure sensor 324 feeds back the signal to the control system, triggering the servo motor 301 to unlock and start. This interlock mechanism ensures that the tube blank is rotated and driven only after reaching a stable clamping state, avoiding the shaking or falling off of the tube blank during rotation due to unstable clamping, and ensuring the safety and stability of the zinc spraying operation.

[0051] In step one, a weighted fusion algorithm was used to fuse the spectrum and image data, with a spectral feature weight coefficient of α = 0.7 and an image feature weight coefficient of β = 0.3. Because the oxide layer is specific in spectral reflectance, while impurities have distinct morphological and textural characteristics, weighted fusion combines the advantages of both spectral and image data modalities to more comprehensively and accurately describe defect characteristics on the tube embryo surface, thereby improving defect identification accuracy. In step two, a transfer learning strategy was adopted. The pre-training dataset was a library of industrial metal surface defects. The pre-training parameter freezing ratio was 60% for convolutional layers and 40% for fully connected layers, and the batch size was set to 32. Freezing some pre-trained parameters preserves the feature representation capabilities learned on a general dataset while allowing the model to be fine-tuned on new tasks, accelerating the model's convergence and improving its generalization performance. A smaller batch size can increase the noise in the gradient estimate, helping to escape local optimal solutions and improve the model's optimization effect. Through this transfer learning method, the improved target detection model can more accurately and quickly identify defects such as oxide layer residues and impurities on the surface of the tube embryo, providing accurate defect information for subsequent defect compensation.

[0052] Second embodiment

[0053] like Figure 4 As shown, the auxiliary spray gun assembly 402 uses a removable tungsten steel nozzle 421 with three outlet aperture options: 2mm, 3mm, and 5mm. A preheating chamber 422 is located between the auxiliary gun assembly's nozzle and the auxiliary gun assembly's powder supply pipe. This chamber houses a spiral resistance wire 423, whose temperature is maintained at 380±5°C by a PID controller 424. Tungsten steel boasts high hardness, wear resistance, and excellent corrosion resistance. Using tungsten steel nozzle 421 ensures that the nozzle is less susceptible to wear and damage during the high-temperature, high-pressure zinc spraying operation. This extends the nozzle's service life, reduces downtime and repairs caused by nozzle damage, and improves overall equipment reliability. The temperature of resistance wire 423 is maintained at 380±5°C by a PID controller 424. PID controller 424 employs an automatic control algorithm that continuously adjusts the heating power of resistance wire 423 to maintain the temperature within the preheating chamber 422 within a set range. Before entering the nozzle, the zinc powder is heated to a certain temperature in the preheating chamber 422, which improves its fluidity. This allows the powder to be ejected more smoothly through the nozzle, reducing clogging. It also allows the powder to be atomized more effectively during the spraying process, forming a uniform flow. This improves the uniformity and adhesion of the zinc spray, ensuring high-quality zinc spraying.

[0054] The above are only specific embodiments of the present invention, but the technical features of the present invention are not limited thereto. Any simple changes, equivalent substitutions or modifications made based on the present invention to solve substantially the same technical problems and achieve substantially the same technical effects are all covered by the protection scope of the present invention.

Claims

1. An automatic hot zinc spraying device, characterized in that: Comprising: A base (1), serving as the foundation of the device; Three groups of annularly evenly distributed zinc spraying gun groups (2), movably connected to the base (1) through an axial position adjusting component. A radial adjusting component is arranged between each group of the zinc spraying gun groups (2) and the axial position adjusting component for adjusting the distance between the spray gun and the surface of the tube blank. An axial angle fine-tuning component is arranged between the zinc spraying gun group (2) and the radial adjusting component; A driving mechanism for driving the rotation of the tube blank, including a servo motor (301) fixedly connected to the base (1). A clamping component is fixedly arranged on the output shaft of the servo motor (301), and the clamping component is used for clamping and locking the outer wall or inner wall of the tube blank; A defect compensation mechanism is arranged on the axial position adjusting component, including a control chip (403), a multispectral analyzer (401) and an auxiliary spray gun group (402). The multispectral analyzer (401) scans the surface topography of the tube blank in real time, identifies the residual oxide layer or impurity area through a machine learning algorithm, and triggers the auxiliary spray gun group (402) to perform local supplementary spraying through the control chip (403). The auxiliary spray gun group (402) is connected to the axial position adjusting component through the radial adjusting component; When the multispectral analyzer (401) identifies a defect and the machine learning model outputs the defect coordinates, the control chip (403) calculates the spraying time window of the auxiliary spray gun according to the rotation speed of the tube blank, and the rotation speed of the tube blank is obtained by the feedback of the encoder of the servo motor (301). Then, the control chip (403) maps the defect area and defect depth output by the machine learning model into the zinc flow rate (Q = K_p × S_defect, S_defect is the defect area) through a PID algorithm, and controls the radial movement compensation distance of the auxiliary spray gun group (402) (Δd = 0.2 × defect depth).

2. The automatic hot zinc spraying device according to claim 1, characterized in that: The axial position adjusting component includes two parallel translation sliders (511) connected to the base (1). The translation sliders (511) are parallel to the axis of the tube blank. The movable parts of the two translation sliders (511) are fixedly connected to an annular movable frame (512). The number of radial adjusting components arranged on the movable frame (512) is four, corresponding to three groups of the zinc spraying gun groups (2) and one group of the auxiliary gun groups respectively.

3. The automatic hot zinc spraying device according to claim 2, characterized in that: The radial adjusting component is set as a telescopic electric cylinder (521) arranged in the radial direction of the tube blank. Its fixed part is fixedly connected to the movable frame (512). The axial angle adjusting component is set as an electric turntable (531) fixedly connected to the movable part of the telescopic electric cylinder. The movable part of the electric turntable (531) is fixedly connected to the zinc spraying gun group (2), and the electric turntable (531) is used for adjusting the included angle between the axis of the zinc spraying gun group (2) and the axis of the tube blank.

4. The automatic hot zinc spraying device according to claim 3, wherein: The clamping assembly includes a rotating frame (321) fixedly connected to the output shaft of the servo motor (301). Clamping cylinders (322) are fixedly arranged on the rotating frame (321) in a circumferentially uniform manner. A clamping arc plate (323) is arranged on the movable part of the clamping cylinder (322) facing the center of the rotating frame (321). A wear-resistant coating is sprayed on the contact surface between the clamping arc plate (323) and the tube blank.

5. An automatic hot zinc spraying device according to claim 1, characterized in that: The machine learning steps of the multispectral analyzer (401) are as follows: Step 1, multimodal data fusion: The multispectral analyzer (401) is used to collect spectral reflectance and surface topography images, and fuse the spectral characteristics of the specific reflectance of the oxide layer with the image characteristics of the impurity morphology and texture. Step 2, improve the object detection model: Use the YOLOv3 model optimized by the Xception backbone network, combined with transfer learning, and the pre-training data set is the industrial metal surface defect library. Step 3, dynamic compensation decision: Based on the defect coordinates, area, and depth obtained by real-time detection combined with machine learning, the parameters of the injection time window, radial position, and zinc flow rate of the auxiliary spray gun are dynamically adjusted through the PID control algorithm.

6. The automatic hot zinc spraying device according to claim 2, characterized in that: The translation sliding table (511) is a ball screw type sliding table, and the movable frame (512) is set as an annular aluminum alloy frame.

7. An automatic hot zinc spraying device according to claim 4, characterized in that: A pressure sensor (324) is arranged between the clamping cylinder (322) and the clamping arc plate (323), and the pressure sensor (324) is interlocked with the servo motor (301); when the clamping force reaches the set threshold, the servo motor (301) is triggered to unlock and start.

8. An automatic hot zinc spraying device according to claim 5, characterized in that: In Step 1, the weighted fusion algorithm is used for the fusion of spectral and image data. The spectral feature weight coefficient α = 0.7, and the image feature weight coefficient β = 0.3; in Step 2, the freezing ratio of the pre-training parameters of transfer learning is 60% for the convolutional layer and 40% for the fully connected layer, and the batch size is set to 32.

9. An automatic hot zinc spraying device according to claim 1, characterized in that: The nozzles of the auxiliary spray gun group (402) adopt detachable tungsten steel nozzles (421), and there are three optional outlet apertures of 2mm, 3mm, and 5mm; a preheating chamber (422) is arranged between the nozzles of the auxiliary gun group and the powder supply pipe of the auxiliary gun group. A spiral resistance wire (423) is arranged inside the preheating chamber (422), and the temperature of the resistance wire (423) is maintained at 380 ± 5 °C by the PID controller (424PID).

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