Intelligent measurement and control tool for thickness of paint film of steel structure

Abstract

The invention belongs to the technical field of corrosion prevention of steel structures, and particularly relates to an intelligent measurement and control tool for the thickness of a paint film of a steel structure. The brush roller fixing frame is composed of a fixing shaft, an arc-shaped connecting rod and a fixing rod, the fixing shaft penetrates through the center pipe, the two ends of the arc-shaped connecting rod are connected with the two ends of the fixing shaft, the fixing rod is fixedly connected with the rear end of the arc-shaped connecting rod, and the fixing rod is of a hollow structure; the magnetic sensor is arranged on the brush roller fixing frame and is used for detecting the intensity of magnetic attraction force with the surface of the steel structure and transmitting detection data in real time; the operation indicator is arranged on the supporting rod and comprises a microprocessor, a display screen, an alarm and a power supply battery, the magnetic sensor is connected with the input end of the microprocessor through a circuit, and the output end of the microprocessor is electrically connected with the display screen and the alarm. According to the tool, a worker can be reminded of a place with insufficient paint film thickness in the painting process at any time in the painting process, so that the worker can conveniently carry out painting work.

Description

Technical Field

[0001] The invention belongs to the technical field of steel structure anti-corrosion, and particularly relates to an intelligent measurement and control tool for the thickness of paint films on steel structures. Background Art

[0002] Steel structures are widely used in construction projects due to their high strength and convenient construction. Paint film coating is the core process of steel structure anti-corrosion, and its thickness directly affects the service life. In traditional painting construction, the construction control of the paint film thickness is to test the anti-corrosion thickness after the paint film is completely dry, and to repaint the areas where the thickness is insufficient. This construction method has the following defects: 1) Inefficient quality control: It relies on manual experience for painting and needs to be re-tested with a paint film meter afterwards. The rework rate is as high as 15%-20%, and the cost of manual re-testing accounts for more than 12% of the construction cost; 2) Insufficient adaptability: Existing equipment (such as vehicle-mounted sprayers) is difficult to adapt to small spaces and curved structures, and only supports steel substrates, and cannot cover non-magnetic materials such as aluminum alloys; 3) Lack of digitalization: There is a lack of construction process data traceability, quality problems are difficult to locate, and it does not meet the information management needs of smart construction sites.

[0003] While existing technologies attempt to achieve thickness detection through sensors, they suffer from low measurement accuracy (error > ±5μm), limited functionality (detection only, not control), and poor environmental adaptability (e.g., temperature influences). Therefore, there is an urgent need for an intelligent tool that integrates application, measurement, and feedback to achieve dynamic control of the paint film thickness of steel structures throughout the entire process. Summary of the Invention

[0004] The technical problem to be solved by the present invention is the high rate of rework and re-painting caused by insufficient thickness of anti-corrosion coating during construction of steel structures.

[0005] The present invention solves the above problems by adopting the following technical solutions: An intelligent measurement and control tool for paint film thickness on steel structures, comprising a brush roller, a brush roller fixing frame, and a support rod, wherein: The brush roller comprises a central tube with bristles arranged on the surface of the central tube; The brush roller fixing frame is composed of a fixed shaft, an arc-shaped connecting rod and a fixed rod. The fixed shaft is inserted into the center tube. The two ends of the arc-shaped connecting rod are connected to the two ends of the fixed shaft. The fixed rod is fixed to the rear end of the arc-shaped connecting rod. The fixed rod is a hollow structure. The magnetic sensor is installed on the brush roller fixing frame to detect the strength of the magnetic attraction with the steel structure surface and transmit the detection data in real time; The operation indicator is arranged on the support rod and includes a microprocessor, a display screen, an alarm and a power supply battery. The magnetic sensor is connected to the input end of the microprocessor through a line, and the output end of the microprocessor is electrically connected to the display screen and the alarm.

[0006] Compared with the prior art, the present invention adopting the above structure has the following beneficial effects: During the construction process, the tool allows the user to directly input the specified paint film thickness into the operating indicator, controlling the coating quality during the painting process. This reduces the number of on-site reworks and reduces both labor and rework costs. The tool's operating indicator is equipped with red and green indicator lights, which constantly alert workers to areas of insufficient paint film thickness during painting, allowing for timely repairs. This facilitates painting and ensures construction quality. Furthermore, the paint film coating controller consists of five components, making it easy to operate, transport, and reuse. If a component becomes damaged, any unit can be replaced, making the paint film coating controller highly adaptable.

[0007] As a preferred embodiment, a further technical solution of the above structure is: The support rod includes: a first sleeve, the front end of which is clamped and fixed with the fixed rod; a core tube, the front end of which is inserted into the first sleeve and further extends into the fixed rod; a second sleeve, which is sleeved on the rear end of the core tube; a rubber pad is provided on the mating surface of the second sleeve and the core tube; the rubber pad is in an expansion fit with the second sleeve and the core tube; The support spring is arranged inside the first sleeve and is sleeved on the outer wall of the core tube. Its front end is fixedly connected to the inner wall of the first sleeve, and its rear end abuts against the end face of the second sleeve; the locking buckle passes through the side wall of the first sleeve, and the inner end contacts the surface of the core tube to limit the core tube.

[0008] The arc-shaped connecting rod is a hollow tube body, and the magnetic sensor is embedded in its port; a slot is provided on the rear end side wall of the support rod, and the operation indicator is installed at the slot position. The circuit is arranged along the tubular cavity of the arc-shaped connecting rod, the fixed rod, the core tube and the second sleeve.

[0009] A threaded hole is provided on the side wall of the first sleeve, and the locking buckle is a bolt. The bolt is installed in the threaded hole, and the inner end of the bolt abuts against the surface of the core tube.

[0010] An annular groove is provided on the surface of the core tube; a through hole is provided on the side wall of the first sleeve; the locking buckle includes a pressing plate, which consists of a front part and a rear part, the front part and the rear part are arranged at an angle, the front part extends to the surface of the through hole and is connected to a pin rod through a pin shaft, the pin rod is slidably set in the through hole and its diameter matches the through hole; an ear plate is fixed to the lower surface of the rear part, the ear plate is connected to the connecting seat through a hinge shaft, the connecting seat is fixed to the surface of the first sleeve, and an anti-torsion spring is mounted on the pin shaft, and the pressure feet at both ends of the anti-torsion spring are respectively in contact with the rear part of the pressing plate and the surface of the first sleeve.

[0011] A rubber sleeve is provided on the outside of the fixing rod. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the internal structure of the first sleeve in the contracted state of the present invention; Figure 3 This is a schematic diagram of the cooperation structure between the second sleeve and the core tube of the present invention; Figure 4 This is a diagram showing the locking core tube state of the locking buckle embodiment of the present invention; Figure 5 This is a diagram of the state where the core tube of the locking buckle embodiment of the present invention is released; Figure 6 This is a schematic diagram of the sensor installation structure of the present invention; Figure 7 It is a schematic diagram of the installation structure of the operation indicator of the present invention.

[0013] In the figure: 1. brush roller; 2. fixed shaft; 3. arc-shaped connecting rod; 4. magnetic sensor; 5. rubber sleeve; 6. fixing rod; 7. first sleeve; 8. locking buckle; 9. support spring; 10. core tube; 11. second sleeve; 12. operation indicator; 13. rubber pad; 14. annular groove; 71. front; 72. rear; 73. pin shaft; 74. pin rod; 75. ear plate; 76. connecting seat. DETAILED DESCRIPTION

[0014] The present invention will be further described below with reference to the embodiments, the purpose of which is only to provide a better understanding of the content of the present invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0015] See also Figures 1 to 7 The intelligent measurement and control tool for the thickness of the paint film on steel structures provided by the present invention comprises a brush roller 1, a brush roller fixing frame and a support rod, wherein: The brush roller 1 includes a central tube with bristles arranged on the surface of the central tube; The brush roller fixing frame is composed of a fixed shaft 2, an arc-shaped connecting rod 3 and a fixed rod 6. The fixed shaft 2 is arranged inside the central tube, the two ends of the arc-shaped connecting rod 3 are connected to the two ends of the fixed shaft 2, and the fixed rod 6 is fixed to the rear end of the arc-shaped connecting rod 3. The fixed rod 6 is a hollow structure. Also includes: The magnetic sensor 4 is provided on the brush roller fixing frame and is used to detect the strength of the magnetic attraction with the steel structure surface and transmit the detection data in real time; The operation indicator 12 is arranged on the support rod. The operation indicator 12 includes a microprocessor, a display screen, an alarm and a power supply battery. The magnetic sensor 4 is connected to the input end of the microprocessor through a line, and the output end of the microprocessor is electrically connected to the display screen and the alarm.

[0016] By inputting a specified paint film thickness during the application process, when the probe (magnetic sensor 4) contacts the coating, it forms a closed magnetic circuit with the magnetic metal substrate. The presence of the paint film causes the magnetic resistance of the magnetic circuit to change, and by measuring this resistance change, the thickness of the paint film can be calculated. The data detected by the magnetic sensor 4 is transmitted to the operating indicator 12, which has a built-in microprocessor and storage module to record the thickness data (including time and position coordinates) in real time. The operating indicator 12 processes the data through its internal microprocessor and transmits the signal to the display. The display determines the status of the paint film by flashing red and green lights: red light indicates insufficient paint film, and green light indicates acceptable paint film.

[0017] The Operation Indicator 12 supports Bluetooth / Wi-Fi wireless transmission, and data is synchronized to the construction management platform to generate traceable quality files. A preset threshold adaptive algorithm automatically matches the standard thickness parameters (such as GB / T 13452.2) based on the substrate type (Q235 / Q345 / aluminum alloy) and paint film type (epoxy zinc-rich / polyurethane).

[0018] The color touch operation interface displays in real time: ① the current thickness value; ② the deviation from the standard value (green within ±5%, red flashing for <-5%, yellow warning for >+5%); ③ the historical painting trajectory heat map (red area indicates insufficient painting, green indicates qualified); the red, green and yellow LED light ring (13) on the operation display surrounds the painting status of the current area; when the thickness is abnormal, the voice announcement hole (9) announces "5μm insufficient painting at 20cm from the 1 o'clock direction, it is recommended to repaint", reducing workers' visual fatigue; when working at height, the handle vibrates to indicate abnormalities to avoid noise interference.

[0019] In this solution, the brush roller fixing frame adopts a stable Y-shaped mechanical structure, which has good support stability for the brush roller 1.

[0020] As an option, the support rod comprises: The front end of the first sleeve 7 is fixedly engaged with the fixing rod 6. The core tube 10 has a front end which is inserted into the first sleeve 7 and further extends into the fixing rod 6; The second sleeve 11 is sleeved on the rear end of the core tube 10. The mating surface of the second sleeve 11 and the core tube 10 is provided with a rubber pad 13. The rubber pad 13 is tightly fitted with the second sleeve 11 and the core tube 10. The support spring 9 is arranged inside the first sleeve 7 and is sleeved on the outer wall of the core tube 10. Its front end is fixedly connected to the inner wall of the first sleeve 7, and its rear end abuts against the end surface of the second sleeve 11; The locking buckle 8 passes through the side wall of the first sleeve 7 , and the inner end contacts the surface of the core tube 10 to limit the core tube 10 .

[0021] The support rod of the present invention cooperates with the fixed rod 6 to form a three-stage telescopic structure with a final extension length of 5m, making it suitable for high-altitude operations. The second sleeve 11 and the core tube 10 generate telescopic damping through a rubber pad 13, allowing manual control of the telescopic length. The core tube 10 is controlled or secured by a locking clip 8. When the locking clip 8 is loose, the core tube 10 is allowed to telescope within the fixed rod 6. When the locking clip 8 is tightened, the core tube 10 is secured, thus ensuring the overall stability of the support rod during use. The rubber pad 13 is made of high-friction silicone rubber (hardness 70±5 Shore A). The rubber pad 13 can be a rubber strip axially arranged on the inner wall of the second sleeve 11 and the outer wall of the core tube 10, or it can be a tube that completely encases the core tube 10.

[0022] As an option, the arc-shaped connecting rod is a hollow tube body, and the magnetic sensor 4 is embedded in its port; a slot is provided on the rear end side wall of the support rod, and the operation indicator 12 is installed at the slot position, and the circuit is arranged along the tubular cavity of the arc-shaped connecting rod 3, the fixed rod 6, the core tube 10 and the second sleeve 11.

[0023] The surface of the brush roller 1 is covered with an elastic silicone layer, which is suitable for steel structure surfaces with a roughness of Ra≤12.5μm.

[0024] The sensor integrates a dual-coil differential magnetic flux sensor (for steel substrates) and an eddy current sensor (for non-magnetic substrates such as aluminum alloys). Automatic mode switching automatically adjusts the sensor to achieve a measurement accuracy of ≤±2μm. The sensor also includes a built-in temperature compensation module, providing real-time correction for the effects of ambient temperature (-20°C to 60°C) on paint film thickness.

[0025] As an embodiment, a threaded hole is provided on the side wall of the first sleeve 7 , and the locking buckle 8 is a bolt. The bolt is installed in the threaded hole, and its inner end abuts against the surface of the core tube 10 .

[0026] As another embodiment, an annular groove 14 is provided on the surface of the core tube 10; a through hole is provided on the side wall of the first sleeve 7; the locking buckle 8 includes a pressing plate, which consists of a front part 71 and a rear part 72, and the front part 71 and the rear part 72 are arranged at an angle, and the front part 71 extends to the surface of the through hole and is connected to a pin rod 74 through a pin shaft 73, and the pin rod 74 is slidably set in the through hole and its diameter matches the through hole; an ear plate 75 is fixed to the lower surface of the rear part 72, and the ear plate 75 is connected to the connecting seat 76 through a hinge shaft, and the connecting seat 76 is fixed to the surface of the first sleeve 7, and an anti-torsion spring is installed on the pin shaft 73, and the pressure feet at both ends of the anti-torsion spring are respectively in contact with the rear part 72 of the pressing plate and the surface of the first sleeve 7.

[0027] Specifically, the annular groove 14 has a depth of 5 cm and a width of 3 cm. The lower end of the pin 74 fits into the annular groove 14. The pin 74 is inserted into the annular groove 14 to constrain the movement of the core tube 10, with a tensile force of ≥50N.

[0028] This solution adopts a double locking mechanism. Specifically, the locking buckle 8 has a positioning accuracy of ±1mm, which mainly solves the problem of axial movement. The rubber pad 13 produces friction damping, which mainly solves the problem of circumferential shaking, ensuring that the tool is stable and has no deviation during high-altitude operations.

[0029] As an option, a rubber sleeve 5 is provided on the outside of the fixing rod 6. The surface of the rubber sleeve 5 is designed with diamond-shaped anti-skid patterns.

[0030] The following describes the use of the above device: 1. Length adjustment stage (unlocked state) When the length of the telescopic rod needs to be adjusted, the worker presses the locking buckle 8, pries the pin 74 up, the core tube 10 loses its limit, and moves outward under the push of the support spring 9. The second sleeve 11 disengages from the first sleeve 7 to release the mechanical lock, thereby allowing the core tube 10 to be pulled out from the fixed rod 6. At the same time, after the second sleeve 11 disengages from the first sleeve 7, the core tube 10 is exposed. The damping structure between the core tube 10 and the second sleeve 11 is not sufficient to resist the manual pulling force. Therefore, when the length is still insufficient, the worker can easily pull out part of the core tube 10 from the second sleeve 11 to achieve length adjustment (adjustment speed ≤ 10 cm / s).

[0031] 2. Locking and fixing stage (working status) When the support rod is stretched to the target length, one end of the core tube 10 is in the second sleeve 11 and is stabilized by the rubber pad 13, and the other end is in the first sleeve 7. The pin rod 74 is pressed against the surface of the core tube 10, and the pressure on its outer surface is greater than the pressure on the bottom of the annular groove 14. The pin rod 74 fixes the other end of the core tube 10, thereby achieving overall stability of the support rod.

[0032] During the construction process, the tool allows the user to directly input the specified paint film thickness into the operating indicator, controlling the coating quality during the painting process. This reduces the number of on-site reworks and reduces both labor and rework costs. The tool's operating indicator is equipped with red and green indicator lights, which constantly alert workers to areas of insufficient paint film thickness during painting, allowing for timely repairs. This facilitates painting and ensures construction quality. Furthermore, the paint film coating controller consists of five components, making it easy to operate, transport, and reuse. If a component becomes damaged, any unit can be replaced, making the paint film coating controller highly adaptable.

[0033] The above description is only a preferred embodiment of the present invention and does not limit the scope of the present invention. Any equivalent changes made using the contents of the present invention specification and its drawings are included in the scope of the present invention.

Claims

1. An intelligent measurement and control tool for the thickness of paint film on steel structures, comprising a brush roller, a brush roller fixing frame and a support rod, characterized in that: in: The brush roller comprises a central tube with bristles arranged on the surface of the central tube; The brush roller fixing frame is composed of a fixed shaft, an arc-shaped connecting rod and a fixed rod. The fixed shaft is inserted into the center tube. The two ends of the arc-shaped connecting rod are connected to the two ends of the fixed shaft. The fixed rod is fixed to the rear end of the arc-shaped connecting rod. The fixed rod is a hollow structure. The magnetic sensor is installed on the brush roller fixing frame to detect the strength of the magnetic attraction with the steel structure surface and transmit the detection data in real time; The operation indicator is arranged on the support rod and includes a microprocessor, a display screen, an alarm and a power supply battery. The magnetic sensor is connected to the input end of the microprocessor through a line, and the output end of the microprocessor is electrically connected to the display screen and the alarm.

2. The intelligent measurement and control tool for paint film thickness of steel structures according to claim 1 is characterized in that: The support rod comprises: The front end of the first sleeve is fixedly connected to the fixing rod. The core tube has a front end which is inserted into the first sleeve and further extends into the fixing rod; The second sleeve is sleeved on the rear end of the core tube, and a rubber pad is provided on the mating surface of the second sleeve and the core tube; the rubber pad is in expansion fit with the second sleeve and the core tube; The support spring is arranged inside the first sleeve and sleeved on the outer wall of the core tube, with its front end fixedly connected to the inner wall of the first sleeve and its rear end abutting against the end surface of the second sleeve; The locking buckle passes through the side wall of the first sleeve, and the inner end contacts the surface of the core tube to limit the core tube.

3. The intelligent measurement and control tool for paint film thickness of steel structures according to claim 2 is characterized in that: The arc-shaped connecting rod is a hollow tube body, and the magnetic sensor is embedded in its port; a slot is provided on the rear end side wall of the support rod, and the operation indicator is installed at the slot position. The circuit is arranged along the tubular cavity of the arc-shaped connecting rod, the fixed rod, the core tube and the second sleeve.

4. The intelligent measurement and control tool for paint film thickness of steel structures according to claim 2 is characterized in that: A threaded hole is provided on the side wall of the first sleeve, and the locking buckle is a bolt. The bolt is installed in the threaded hole, and the inner end of the bolt abuts against the surface of the core tube.

5. The intelligent measurement and control tool for paint film thickness of steel structures according to claim 2 is characterized in that: An annular groove is provided on the surface of the core tube; a through hole is provided on the side wall of the first sleeve; the locking buckle includes a pressing plate, which consists of a front part and a rear part, the front part and the rear part are arranged at an angle, the front part extends to the surface of the through hole and is connected to a pin rod through a pin shaft, the pin rod is slidably set in the through hole and its diameter matches the through hole; an ear plate is fixed to the lower surface of the rear part, the ear plate is connected to the connecting seat through a hinge shaft, the connecting seat is fixed to the surface of the first sleeve, and an anti-torsion spring is mounted on the pin shaft, and the pressure feet at both ends of the anti-torsion spring are respectively in contact with the rear part of the pressing plate and the surface of the first sleeve.

6. The intelligent measurement and control tool for paint film thickness of steel structures according to claim 1 is characterized by: A rubber sleeve is provided on the outside of the fixing rod.

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