Intelligent insulation detection and multi-nozzle insulating paint accurate spraying device and method

Abstract

The invention discloses an intelligent insulation detection and multi-nozzle insulating paint accurate spraying device and method.The device comprises a basic supporting mechanism, a first moving frame and a second moving frame, the basic supporting mechanism is a portal frame, and first lead screws and auxiliary guide rods are rotationally arranged between the upper ends and the lower ends of the two sides of the portal frame; according to the spraying device, the top end, the upper side, the lower side, the left side, the right side and other faces of the space to be sprayed of the switch cabinet can be completely coated through the multiple sprayers, the detection tools on all the units can synchronously detect the spraying area, the spraying device can adapt to the multi-layer drawer type special space of the switch cabinet, and operation can be conducted without disassembling components of the switch cabinet; in image preprocessing, through Gaussian filtering, temperature compensation and light intensity normalization, environmental interference is effectively eliminated; the output pressure of the energy supply and material supply equipment is adjusted in real time through a PID algorithm to offset the paint layer thickness deviation, the swing angle of the spray head is compensated in combination with environment humidity, and different humidity environments are adapted.

Description

Technical Field

[0001] This invention relates to the field of electrical equipment insulation treatment technology, specifically to an intelligent insulation detection and multi-nozzle precision spraying device and method for insulating varnish. Background Technology

[0002] Switchgear is the core equipment for power distribution, control, and protection in power systems. Its internal insulation performance directly determines the safety and reliability of power system operation. As power systems develop towards higher voltage and larger capacity, the insulation level requirements for switchgear are becoming increasingly stringent, making insulating varnish coating a key process for improving its insulation performance. However, some switchgear uses a special multi-layer drawer-type structure with a closed internal space and complex structure. At the same time, the accurate identification and differentiated repair of insulation defects such as scratches and stains are also important aspects of ensuring insulation quality. All of these factors bring many limitations to insulation testing and varnish spraying operations.

[0003] First, the internal space of the switch cabinet is narrow and in a closed or semi-closed state. Traditional insulation testing and spraying devices are mostly manual or fixed structures, which are difficult to adapt to the special spatial layout of its multi-layer drawers. If the work is carried out by disassembling switch cabinet components, it is not only time-consuming and laborious, but also easy to introduce new safety hazards during the disassembly and assembly process, which seriously affects the convenience and safety of the work.

[0004] Secondly, the surface defects of the insulation components inside the switch cabinet are complex, covering various forms such as scratches and stains. Existing defect detection algorithms often use edge detection methods with fixed thresholds or single feature recognition methods, which are significantly affected by changes in ambient light intensity and temperature fluctuations. They suffer from problems such as incomplete defect contour extraction and low accuracy in defect type judgment, and cannot provide accurate defect location and type information for subsequent insulating paint spraying.

[0005] In addition, in the process of insulating varnish spraying, traditional spraying equipment mostly adopts a unidirectional, fixed parameter spraying mode, which makes it difficult to carry out differentiated spraying for different types of defect areas, lacks a dynamic compensation mechanism for external factors such as environmental humidity, and the re-inspection and re-spraying strategy for the quality of the varnish layer after spraying is not perfect, which easily leads to uneven varnish layer thickness and missed spraying, making it difficult for the quality of insulating varnish coating to meet the requirements of high insulation performance.

[0006] Therefore, it is necessary to design an intelligent insulation detection and multi-nozzle precision spraying device and method for insulating varnish. Summary of the Invention

[0007] The purpose of this invention is to provide an intelligent insulation detection and multi-nozzle insulation varnish precision spraying device and method to solve the problems mentioned in the background art, such as poor adaptability of traditional devices due to the special internal space of switchgear, cumbersome disassembly and assembly operations that are prone to introducing hidden dangers, large environmental interference and low identification accuracy of defect detection, and poor coating quality due to the difficulty in differentiating insulation varnish spraying and the lack of dynamic compensation and perfect respraying strategies.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] In a first aspect, an intelligent insulation detection and multi-nozzle insulation paint precision spraying device is provided, including a basic support mechanism, a first movable frame and a second movable frame. The basic support mechanism is a gantry frame. A first lead screw and an auxiliary guide rod are rotatably arranged between the upper and lower ends on both sides of the gantry frame. A first connector is screwed onto the first lead screw, and a second connector is slidably connected to the auxiliary guide rod. The first connector and the second connector are both fixedly connected to both sides of the first movable frame.

[0010] A first motor is fixedly connected to the gantry frame. The output end of the first motor passes through the gantry frame and is driven to one of the first lead screws. The two first lead screws are connected by a first synchronous belt. First lead screws are provided on both sides of the gantry frame and synchronous transmission is achieved through the first synchronous belt. This solves the technical problem that single-sided lead screw drive can easily cause the first moving frame to tilt up and down. It makes the first moving frame bear the force evenly and is suitable for multi-layer drawer-type spraying space in switch cabinet.

[0011] The second movable frame is slidably disposed within the first movable frame, and a multi-directional spraying mechanism is provided at the end of the second movable frame away from the gantry.

[0012] The multi-directional spraying mechanism includes a top spraying unit, upper and lower spraying units, and left and right spraying units. Each unit is equipped with a detection tool and its angle is adjustable. The division of the top spraying unit, upper and lower spraying units, and left and right spraying units precisely matches the top, upper and lower, and left and right five-sided structure of the switch cabinet drawer-type space to be sprayed. The angle-adjustable design of each unit can adjust the spraying angle of the nozzle according to the surface curvature or edge structure of the insulating component to be sprayed, ensuring uniform paint coverage.

[0013] It also includes power and material supply equipment mounted on the second moving frame.

[0014] As a further technical solution of the present invention, the second moving frame is slidably disposed in the first moving frame by a propulsion mechanism. The propulsion mechanism includes sliders fixedly connected to both sides of the second moving frame. The sliders are limited and slidably connected to slide rails disposed on both sides of the first moving frame. A second lead screw is rotatably connected in the slide rails. The second lead screw is screwed into the slider. A second motor is fixedly connected to one side of the first moving frame. The output end of the second motor passes through the first moving frame and drives one of the second lead screws. The two second lead screws are connected by a second synchronous belt.

[0015] As a further technical solution of the present invention, there are multiple top spraying units and left and right spraying units, which are respectively arranged at the top and left and right sides of the second moving frame away from the gantry frame. Each top spraying unit and left and right spraying unit includes two sets of symmetrically distributed first nozzles.

[0016] A first mounting plate and a bidirectional motor are fixedly connected to the second movable frame. The bidirectional motor is located between the first mounting plates. The output ends of the bidirectional motor are all driven to connect to a first connecting rod. The first connecting rod is rotatably connected to the first mounting plate and is fixedly connected to a first nozzle. The adjacent top spraying units overlap in their spraying coverage areas by rotating. The left and right end spraying units include diagonal areas in their spraying coverage areas by rotating.

[0017] The detection tool is fixedly connected to the first nozzle.

[0018] As a further technical solution of the present invention, there are multiple upper and lower spraying units, which are arranged on the upper and lower sides of the second moving frame away from the gantry frame. Each unit includes at least one set of second nozzles. A third motor and a second mounting plate are fixedly connected to the second moving frame. The output end of the third motor drives and connects to a second connecting rod. The second connecting rod is rotatably connected to the second mounting plate and is fixedly connected to a second nozzle. The adjacent upper and lower spraying units overlap in their spraying coverage areas by rotating.

[0019] The detection tool is fixedly connected to the second nozzle.

[0020] As a further technical solution of the present invention, the detection tool includes an industrial camera equipped with a supplementary light, and the industrial camera is oriented towards the spraying area.

[0021] Secondly, a method for intelligent insulation detection and precise spraying of multi-nozzle insulating varnish is provided, including the following steps:

[0022] S1: Height Adaptation: The control system receives the height parameters of the multi-layer space to be sprayed in the switch cabinet, drives the first motor to move the first moving frame along the first lead screw until the height of the first moving frame matches the space to be sprayed, and locks the position.

[0023] S2: Defect Detection and Location:

[0024] S21: Image acquisition: Drive the second motor to make the second moving frame extend into the spraying space at a preset speed. The industrial camera simultaneously acquires the surface image of the insulating part to be sprayed. The supplementary light dynamically adjusts the brightness according to the ambient light intensity.

[0025] S22: Image preprocessing: Gaussian filtering for noise reduction, temperature compensation, and light intensity normalization are performed sequentially on the acquired raw image to obtain a standardized image;

[0026] S23: Defect identification: The Canny edge detection algorithm is used to extract defect contours from the standardized image, and the defect type is identified by contour feature parameters;

[0027] S24: Physical positioning: Combining the extension distance of the second moving frame and the height position of the first moving frame, establish a mapping model between image coordinates and physical coordinates, and output the three-dimensional physical coordinates of each defect area;

[0028] S3: Dynamic Precision Spraying

[0029] S31: Basic parameter configuration: Set the movement speed of the second moving frame. Sprayer head reference flow rate Reference swing angle and target paint layer thickness ;

[0030] S32: Defect Area Parameter Adjustment: Parameters are adjusted differently for different types of defects: the flow rate in the scratch area is adjusted as follows. Movement speed adjusted to The flow rate in the stained area was adjusted to... Movement speed adjusted to ,in This is a correction factor;

[0031] S33: Real-time closed-loop control: During the spraying process, industrial cameras are used to acquire real-time images of the paint layer and extract paint layer thickness feature values. , with target thickness The comparison yielded the deviation. The output pressure of the power and material supply equipment is adjusted by a PID algorithm, so that... Approaching Simultaneously, the nozzle oscillation angle is compensated in real time according to the ambient humidity.

[0032] S4: Quality Re-inspection and Touch-up Spraying: After the spraying is completed, the second moving frame extends into the spraying space again. The industrial camera collects images of the paint layer in the entire area. The paint layer uniformity detection algorithm determines whether there are any missed spraying areas or areas with unqualified thickness. If so, step S3 is repeated for touch-up spraying until all areas are qualified.

[0033] As a further technical solution of the present invention, in S22, the Gaussian filtering formula is:

[0034]

[0035] in, For the original image, Standard deviation Gaussian kernel, This is a convolution operation;

[0036] The temperature compensation formula is:

[0037]

[0038] in, For temperature coefficient, For real-time ambient temperature, Standard temperature;

[0039] The formula for normalizing light intensity is:

[0040]

[0041] in, Standard light intensity, To measure the actual light intensity, This is the preprocessed image.

[0042] As a further technical solution of the present invention, in S23, the Canny edge detection algorithm is as follows:

[0043] Preprocessed image Calculate gradient magnitude and gradient direction Dynamically determine dual thresholds based on the statistical characteristics of gradient magnitude:

[0044] High threshold:

[0045]

[0046] Low threshold:

[0047]

[0048] in, The mean of the gradient magnitude. For high threshold coefficients, Low threshold coefficient;

[0049] After preserving edge details through non-maximum suppression, a gradient-direction-based edge connection strategy is adopted to enhance and connect weak edges with consistent gradient directions to form a complete defect contour. In the preprocessed image, defect edges may be broken due to noise interference or uneven illumination. If only non-maximum suppression is used to preserve edges, the defect contour may be incomplete, affecting subsequent type recognition. The gradient-direction-based edge connection strategy determines whether the gradient directions of adjacent weak edges are consistent and stitches the broken weak edges into a complete contour.

[0050] Defect type identification is achieved through multi-feature fusion:

[0051] Set the aspect ratio threshold Perimeter-area ratio threshold When the aspect ratio of the outline And the perimeter area ratio When the aspect ratio of the outline is... And the perimeter area ratio When the time is right, it is judged as a stain defect; among which the aspect ratio threshold is... Perimeter-area ratio threshold Obtained through training with samples;

[0052] Select aspect ratio Ratio of perimeter to area As a defect classification characteristic, it is based on the morphological differences of common defects in switchgear insulation components: scratch defects are usually elongated strips with a length-to-width ratio of... Larger, and the ratio of perimeter to area is... Larger; stain defects are usually blocky or irregularly round, with a length-to-width ratio of Smaller, and Smaller;

[0053] Traditional Canny edge detection algorithms use fixed dual thresholds, such as TH=100 and TL=50. In complex lighting conditions inside switch cabinets, such as localized strong light and shadow, this can easily lead to missed weak edges or false positives due to noise. In this design, the average gradient magnitude is used... The threshold is dynamically determined and can be adaptively adjusted according to the actual edge strength of the image;

[0054] In step S24, the three-dimensional physical coordinate mapping model is as follows:

[0055]

[0056]

[0057]

[0058] in, The three-dimensional physical coordinates of the defect For image coordinates, This is the scaling factor. This is the initial offset. This is the compensation amount that varies with the extension distance L of the secondary guide rail. For the height of the main rail frame, This is the correction amount in the height direction.

[0059] As a further technical solution of the present invention, in S33, the expression of the PID control algorithm is:

[0060]

[0061] in, For the booster pump output pressure, For thickness deviation, These are the proportional, integral, and differential coefficients, respectively.

[0062] The formula for humidity compensation angle is: ,in To compensate for the subsequent swing angle, Humidity coefficient For real-time humidity, The standard humidity is used; the core function of the PID algorithm is to correct the output pressure of the booster pump in real time. To compensate for paint layer thickness deviations caused during the spraying process To mitigate interference factors such as changes in paint viscosity and slight fluctuations in nozzle distance, ensure the actual paint layer thickness. Approaching the target thickness .

[0063] As a further technical solution of the present invention, the paint layer uniformity detection algorithm in S4 includes:

[0064] Calculate the standard deviation of gray values ​​in the paint layer image. ,when It is judged to be uniform at that time. The preset threshold;

[0065] Calculate the deviation rate between the paint layer thickness and the target thickness in each area. ,when The thickness was deemed acceptable at that time. This is the deviation threshold;

[0066] After marking the non-conforming areas, a touch-up spraying path is generated. The touch-up spraying path uses a spiral scanning trajectory to ensure the overlap between the touch-up spraying area and the original spraying area. .

[0067] Compared with existing technologies, the advantages of this intelligent insulation detection and multi-nozzle precision spraying device and method for insulating varnish are:

[0068] The gantry frame, through the cooperation of the first lead screw and the auxiliary guide rod on both sides, can drive the first and second moving frames to smoothly extend into the switch cabinet and accurately match the height of the space to be sprayed. The multi-directional spraying mechanism includes a top spraying unit, upper and lower spraying units, and left and right spraying units, which can be angled. With the help of multiple nozzles, it can achieve full coating of the top, upper and lower sides, left and right sides of the space to be sprayed in the switch cabinet. The detection tools on each unit can simultaneously detect the sprayed area, providing accurate basis for the spraying operation and ensuring the comprehensiveness and uniformity of the insulating paint coating. It can adapt to the special space of the multi-layer drawer type of switch cabinet and can be operated without disassembling switch cabinet components.

[0069] Image preprocessing effectively eliminates environmental interference through Gaussian filtering, temperature compensation, and light intensity normalization; the Canny edge detection algorithm dynamically determines dual thresholds based on gradient magnitude statistical features and connects edges in combination with gradient direction, enabling complete extraction of defect contours; the multi-feature fusion defect recognition method distinguishes between scratches and stains using parameters such as aspect ratio and perimeter-area ratio, ensuring accurate defect type identification; the three-dimensional physical coordinate mapping model introduces compensation amounts based on moving distance and height, accurately locating the physical position of defects and providing precise positional information for differentiated spraying.

[0070] During dynamic spraying, spraying parameters are adjusted based on the differences in defect types. The output pressure of the power supply and material supply equipment is adjusted in real time through a PID algorithm to offset the deviation in paint layer thickness. Combined with environmental humidity compensation, the nozzle swing angle is adapted to different humidity environments. For quality re-inspection, a paint layer uniformity detection algorithm is used to judge the paint layer status. For unqualified areas, a spiral re-spraying path is used to ensure that the re-sprayed area fully overlaps with the original sprayed area, ultimately achieving uniform and qualified paint layer coverage on the surface to be sprayed. Attached Figure Description

[0071] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0072] Figure 2 for Figure 1 Enlarged view of the local structure of region A in the middle;

[0073] Figure 3 This is a schematic diagram of the method flow of the present invention;

[0074] In the diagram: 1. Gantry frame; 2. First moving frame; 3. Second moving frame; 4. Multi-directional spraying mechanism; 41. Top spraying unit; 42. Upper and lower spraying units; 43. Left and right spraying units; 5. Propulsion mechanism; 11. First lead screw; 12. Auxiliary guide rod; 13. First connector; 14. Second connector; 15. First motor; 16. First synchronous belt; 31. First mounting plate; 32. Second mounting plate; 33. Power and material supply equipment; 44. Detection tool; 401. First nozzle; 402. First connecting rod; 403. Bidirectional motor; 404. Second nozzle; 405. Third motor; 406. Second connecting rod; 51. Slider; 52. Slide rail; 53. Second lead screw; 54. Second motor; 55. Second synchronous belt. Detailed Implementation

[0075] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0076] Please see the appendix Figure 1 -Appendix Figure 2 The present invention provides an embodiment 1: an intelligent insulation detection and multi-nozzle insulation paint precision spraying device, including a basic support mechanism, a first movable frame 2 and a second movable frame 3. The basic support mechanism is a gantry frame 1. A first lead screw 11 and an auxiliary guide rod 12 are rotatably arranged between the upper and lower ends on both sides of the gantry frame 1. A first connector 13 is screwed onto the first lead screw 11. A second connector 14 is slidably connected to the auxiliary guide rod 12. The first connector 13 and the second connector 14 are both fixedly connected to both sides of the first movable frame 2.

[0077] A first motor 15 is fixedly connected to the gantry frame 1. The output end of the first motor 15 passes through the gantry frame 1 and is driven to one of the first lead screws 11. The two first lead screws 11 are connected by a first synchronous belt 16. First lead screws 11 are set on both sides of the gantry frame 1 and synchronous transmission is achieved through the first synchronous belt 16. This solves the technical problem that single-sided lead screw drive can easily cause the first moving frame 2 to tilt up and down, making the first moving frame 2 bear the force evenly and adapting to the multi-layer drawer-type spraying space in the switch cabinet.

[0078] The second moving frame 3 is slidably disposed in the first moving frame 2, and a multi-directional spraying mechanism 4 is provided at the end of the second moving frame 3 away from the gantry frame 1; the second moving frame 3 is slidably disposed in the first moving frame 2 through a pushing mechanism 5, the pushing mechanism 5 including sliders 51 fixedly connected to both sides of the second moving frame 3, the sliders 51 being limited and slidably connected to slide rails 52 disposed on both sides of the first moving frame 2, a second lead screw 53 being rotatably connected in the slide rails 52, the second lead screw 53 being screwed into the sliders 51, a second motor 54 being fixedly connected to one side of the first moving frame 2, the output end of the second motor 54 passing through the first moving frame 2 and driving one of the second lead screws 53, the two second lead screws 53 being connected by a second synchronous belt 55;

[0079] The multi-directional spraying mechanism 4 includes a top spraying unit 41, upper and lower spraying units 42, and left and right spraying units 43. Each unit is equipped with a detection tool 44, and each unit is angle-adjustable. The division of the top spraying unit 41, upper and lower spraying units 42, and left and right spraying units 43 precisely matches the top, upper and lower, and left and right sides of the switch cabinet drawer-type space to be sprayed. The angle-adjustable design of each unit allows for adjustment of the nozzle spraying angle according to the surface curvature or edge structure of the insulating component to be sprayed, ensuring uniform paint coverage. There are multiple top spraying units 41 and left and right spraying units 43, which are respectively located at the top and left and right sides of the second moving frame 3 away from the gantry 1. Each top spraying unit 41 and left and right spraying unit 43 includes two sets of symmetrically distributed first nozzles 401. A first mounting plate 31 and a bidirectional motor 403 are fixedly connected to the second moving frame 3. The bidirectional motor 403 is located between the first mounting plates 31, and the output ends of the bidirectional motor 403 are all... A first connecting rod 402 is driven and connected to a first mounting plate 31. The first connecting rod 402 is rotatably connected to a first nozzle 401. Adjacent top spraying units 41 rotate to overlap their spraying coverage areas. Left and right spraying units 43 rotate to cover their diagonal areas. A detection tool 44 is fixedly connected to the first nozzle 401. Multiple upper and lower spraying units 42 are located on the upper and lower sides of the second moving frame 3 away from the gantry 1. Each unit includes at least one set of second nozzles 404. A third motor 405 and a second mounting plate 32 are fixedly connected to the second moving frame 3. The output end of the third motor 405 is driven and connected to a second connecting rod 406. The second connecting rod 406 is rotatably connected to the second mounting plate 32 and fixedly connected to the second nozzle 404. Adjacent upper and lower spraying units 42 rotate to overlap their spraying coverage areas. A detection tool 44 is fixedly connected to the second nozzle 404.

[0080] Inspection tool 44 includes an industrial camera equipped with a supplementary light and facing the spraying area;

[0081] It also includes a power supply and material supply device 33 installed on the second moving frame 3.

[0082] Working principle: When in use, after the control system receives the height parameter of the space to be sprayed, it drives the first motor 15 fixed on the gantry 1 to start; the output end of the first motor 15 passes through the gantry 1 and directly drives the first lead screw 11 on one side to rotate; the first lead screws 11 on both sides achieve synchronous rotation through the first synchronous belt 16, avoiding tilting caused by unilateral drive;

[0083] The first connecting piece 13 screwed on the first lead screw 11 moves axially as the lead screw rotates, while the second connecting piece 14 slidably connected on the auxiliary guide rod 12 provides guidance and constraint. Together, they drive the first moving frame 2 to move smoothly in the up and down direction until the height of the first moving frame 2 matches the space to be sprayed. The control system locks the position of the first moving frame 2 to complete the height adaptation.

[0084] The control system drives the second motor 54 fixed on the side of the first moving frame 2 to start. The output end of the second motor 54 drives the second lead screw 53 on one side to rotate. The second lead screws 53 on both sides rotate synchronously through the second synchronous belt 55 and engage with the sliders 51 fixed on both sides of the second moving frame 3, driving the second moving frame 3 to smoothly extend into the space to be sprayed along the slide rails 52 on both sides of the first moving frame 2.

[0085] As the second moving frame 3 extends in, the detection tools 44 fixed on each unit of the multi-directional spraying mechanism 4 at its front end start synchronously: the supplementary light dynamically adjusts its brightness according to the ambient light intensity, the industrial camera collects images of the surface of the insulating part to be sprayed in real time, and the image data is transmitted to the control system.

[0086] If there are corners or edge areas in the space to be sprayed, the bidirectional motors 403 corresponding to the top spraying unit 41 and the left and right spraying units 43 are started, and the first nozzle 401 is driven to swing synchronously through the first connecting rod 402 to ensure that the camera covers the diagonal area; the third motor 405 of the upper and lower spraying units 42 drives the second connecting rod 406 to drive the second nozzle 404 to rotate, so that the camera covers the upper and lower surfaces of the partition without any blind spots.

[0087] Based on the defect detection results, the control system sets the basic parameters: the moving speed of the second moving frame 3. Reference flow rates of the first nozzle 401 and the second nozzle 404 Reference swing angle Target paint layer thickness ;

[0088] The bidirectional motor 403 drives the first connecting rod 402 to swing the two sets of symmetrical first nozzles 401. The adjacent top spraying units 41 swing to achieve partial overlap of the spraying coverage area, avoiding missed spraying. The left and right end spraying units 43 swing to cover the diagonal area of ​​the space to be sprayed, ensuring that there are no dead corners at the edges.

[0089] The third motor 405 drives the second connecting rod 406 to rotate the second nozzle 404. The adjacent upper and lower spraying units 42 achieve overlapping coverage by rotating, adapting to the upper and lower surfaces of the insulating partition.

[0090] After the spraying is completed, the second motor 54 drives the second moving frame 3 to extend into the spraying space again, and the detection tool 44 collects the paint layer image of the whole area, focusing on detecting the paint layer thickness and uniformity.

[0091] If the control system determines that there are areas with missed spraying or unqualified thickness through the paint layer uniformity detection algorithm, the dynamic spraying steps are repeated: the bidirectional motor 403 and the third motor 405 drive the corresponding nozzles to adjust the angle, the power supply and material supply equipment 33 adjusts the flow rate and pressure, and the second moving frame 3 moves according to the re-spraying path until the re-inspection is qualified.

[0092] Please see the appendix Figure 3 The present invention provides an embodiment 2: an intelligent insulation detection and multi-nozzle precise spraying method for insulating varnish, comprising the following steps:

[0093] S1: Height Adaptation: The control system receives the height parameters of the multi-layer space to be sprayed in the switch cabinet, drives the first motor 15 to move the first moving frame 2 along the first lead screw 11 until the height of the first moving frame 2 matches the space to be sprayed, and locks the position.

[0094] S2: Defect Detection and Location:

[0095] S21: Image acquisition: Drive the second motor 54 to make the second moving frame 3 extend into the space to be sprayed at a preset speed. The industrial camera simultaneously acquires the surface image of the insulating part to be sprayed. The supplementary light dynamically adjusts the brightness according to the ambient light intensity.

[0096] S22: Image preprocessing: Gaussian filtering for noise reduction, temperature compensation, and light intensity normalization are performed sequentially on the acquired raw image to obtain a standardized image;

[0097] The Gaussian filtering formula is:

[0098]

[0099] in, For the original image, Standard deviation Gaussian kernel, This is a convolution operation;

[0100] The temperature compensation formula is:

[0101]

[0102] in, For temperature coefficient, For real-time ambient temperature, Standard temperature;

[0103] The formula for normalizing light intensity is:

[0104]

[0105] in, Standard light intensity, To measure the actual light intensity, The image after preprocessing;

[0106] S23: Defect identification: The Canny edge detection algorithm is used to extract defect contours from the standardized image, and the defect type is identified by contour feature parameters;

[0107] The Canny edge detection algorithm is as follows:

[0108] Preprocessed image Calculate gradient magnitude and gradient direction Dynamically determine dual thresholds based on the statistical characteristics of gradient magnitude:

[0109] High threshold:

[0110]

[0111] Low threshold:

[0112]

[0113] in, The mean of the gradient magnitude. For high threshold coefficients, Low threshold coefficient;

[0114] After preserving edge details through non-maximum suppression, a gradient-direction-based edge connection strategy is adopted to enhance and connect weak edges with consistent gradient directions to form a complete defect contour. In the preprocessed image, defect edges may be broken due to noise interference or uneven illumination. If only non-maximum suppression is used to preserve edges, the defect contour may be incomplete, affecting subsequent type recognition. The gradient-direction-based edge connection strategy determines whether the gradient directions of adjacent weak edges are consistent and stitches the broken weak edges into a complete contour.

[0115] Defect type identification is achieved through multi-feature fusion:

[0116] Set the aspect ratio threshold Perimeter-area ratio threshold When the aspect ratio of the outline And the perimeter area ratio When the aspect ratio of the outline is... And the perimeter area ratio When the time is right, it is judged as a stain defect; among which the aspect ratio threshold is... Perimeter-area ratio threshold Obtained through training with samples;

[0117] Select aspect ratio Ratio of perimeter to area As a defect classification characteristic, it is based on the morphological differences of common defects in switchgear insulation components: scratch defects are usually elongated strips with a length-to-width ratio of... Larger, and the ratio of perimeter to area is... Larger; stain defects are usually blocky or irregularly round, with a length-to-width ratio of Smaller, and Smaller;

[0118] Traditional Canny edge detection algorithms use fixed dual thresholds, such as TH=100 and TL=50. In complex lighting conditions inside switch cabinets, such as localized strong light and shadow, this can easily lead to missed weak edges or false positives due to noise. In this design, the average gradient magnitude is used... The threshold is dynamically determined and can be adaptively adjusted according to the actual edge strength of the image;

[0119] S24: Physical positioning: Combining the extension distance of the second moving frame 3 and the height position of the first moving frame 2, establish a mapping model between image coordinates and physical coordinates, and output the three-dimensional physical coordinates of each defect area;

[0120] The three-dimensional physical coordinate mapping model is as follows:

[0121]

[0122]

[0123]

[0124] in, The three-dimensional physical coordinates of the defect For image coordinates, This is the scaling factor. This is the initial offset. This is the compensation amount that varies with the extension distance L of the secondary guide rail. For the height of the main rail frame, This is the correction amount in the height direction;

[0125] S3: Dynamic Precision Spraying

[0126] S31: Basic parameter configuration: Set the movement speed of the second moving frame 3 Sprayer head reference flow rate Reference swing angle and target paint layer thickness ;

[0127] S32: Defect Area Parameter Adjustment: Parameters are adjusted differently for different types of defects: the flow rate in the scratch area is adjusted as follows. Movement speed adjusted to The flow rate in the stained area was adjusted to... Movement speed adjusted to ,in This is a correction factor;

[0128] S33: Real-time closed-loop control: During the spraying process, industrial cameras are used to acquire real-time images of the paint layer and extract paint layer thickness feature values. , with target thickness The comparison yielded the deviation. The output pressure of the power supply and material supply equipment 33 is adjusted by the PID algorithm, so that... Approaching Simultaneously, the nozzle oscillation angle is compensated in real time according to the ambient humidity.

[0129] The expression for the PID control algorithm is:

[0130]

[0131] in, For the booster pump output pressure, For thickness deviation, These are the proportional, integral, and differential coefficients, respectively.

[0132] The formula for humidity compensation angle is: ,in To compensate for the subsequent swing angle, Humidity coefficient For real-time humidity, The standard humidity is used; the core function of the PID algorithm is to correct the output pressure of the booster pump in real time. To compensate for paint layer thickness deviations caused during the spraying process To mitigate interference factors such as changes in paint viscosity and slight fluctuations in nozzle distance, ensure the actual paint layer thickness. Approaching the target thickness ;

[0133] S4: Quality re-inspection and touch-up spraying: After the spraying is completed, the second moving frame 3 extends into the space to be sprayed again. The industrial camera collects the paint layer image of the entire area. The paint layer uniformity detection algorithm determines whether there are any missed spraying or unqualified thickness areas. If so, step S3 is repeated for touch-up spraying until all areas are qualified.

[0134] The algorithm for detecting paint layer uniformity includes:

[0135] Calculate the standard deviation of gray values ​​in the paint layer image. ,when It is judged to be uniform at that time. The preset threshold;

[0136] Calculate the deviation rate between the paint layer thickness and the target thickness in each area. ,when The thickness was deemed acceptable at that time. This is the deviation threshold;

[0137] After marking the non-conforming areas, a touch-up spraying path is generated. The touch-up spraying path uses a spiral scanning trajectory to ensure the overlap between the touch-up spraying area and the original spraying area. .

[0138] An embodiment 3 provided by the present invention: Target object: 3 layers of insulating partitions inside a 10kV high-voltage switchgear, each layer with a thickness of 4mm, and the area to be sprayed is 600mm×400mm;

[0139] Environmental parameters: Real-time ambient temperature Standard temperature Real-time ambient humidity Standard humidity Actual collected light intensity Standard light intensity ;

[0140] Basic spraying parameters: Second moving frame 3 reference moving speed nozzle reference flow rate Reference swing angle Target paint layer thickness ;

[0141] Algorithm coefficient preset: temperature coefficient Gaussian kernel standard deviation High threshold coefficient Low threshold coefficient Scaling factor Initial offset Humidity coefficient PID coefficients ;

[0142] Preprocessing of raw images captured by industrial cameras:

[0143] Gaussian filtering for noise reduction: Substitute into the formula Among them, Gaussian kernel The noise caused by dust in the image is eliminated by convolution operation, resulting in a filtered image. ;

[0144] Temperature compensation: Substitute into the formula Calculated Correcting the effect of temperature on image grayscale values;

[0145] Light intensity normalization: Substitute into the formula Calculated Images under different light intensities are standardized to a standard light intensity to ensure consistency in subsequent defect identification;

[0146] Canny edge detection:

[0147] 1. Calculate the standardized image gradient magnitude and gradient direction The average gradient magnitude was obtained statistically. ;

[0148] 2. Dynamically determine dual thresholds: high threshold low threshold ;

[0149] 3. Non-maximum suppression: Retain pixels with local maxima along the gradient direction and discard non-edge pixels;

[0150] 4. Edge Connection: Weak edges with consistent gradient directions are enhanced and connected, ultimately extracting two defect contours:

[0151] Defect 1: The aspect ratio of the profile is R=4, and the perimeter-to-area ratio is P / S=0.9;

[0152] Defect 2: The aspect ratio of the profile is R=2, and the perimeter-to-area ratio is P / S=0.6;

[0153] Defect type determination: Threshold obtained through sample training ,therefore:

[0154] Defect 1: R=4≥3, P / S=0.9≥0.8, judged as a scratch defect;

[0155] Defect 2: R=2<3, P / S=0.6<0.8, judged as a stain defect;

[0156] 3D physical positioning: Assume the second moving frame 3 extends a distance L = 500mm, the first moving frame 2 has a height H = 220mm, and the coordinates of defect 1 in the image are (u = 400, v = 300). Substitute these coordinates into the mapping model:

[0157] mm, The compensation amount is 0.2 mm when L = 500 mm, which was determined experimentally.

[0158] mm, The compensation amount is calibrated to 0.1mm when L=500mm;

[0159] mm, The height correction amount is calibrated to 0.5 mm;

[0160] The final output of the three-dimensional physical coordinates of defect 1 is (22.2mm, 14.1mm, 220.5mm), and the same calculation is performed for defect 2, which is (85.3mm, 210.2mm, 220.5mm).

[0161] Defect area parameter adjustment:

[0162] Defect 1: Traffic mL / min, This is the scratch flow correction factor, and the moving speed. cm / s, This is the scratch speed correction factor;

[0163] Defect 2: Traffic mL / min, For stain flow correction factor, moving speed cm / s, This is a correction factor for stain velocity.

[0164] Humidity compensation: Substitute into the formula Calculated °, the control system drives the bidirectional motor 403 to adjust the spray head swing angle to 36°, to avoid uneven paint adhesion caused by humidity;

[0165] PID closed-loop control: Industrial camera collects real-time data on paint thickness in defect area 1. Thickness deviation Substitute into the PID formula:

[0166]

[0167] Assume the integral term μm·s, differential term μm / s, calculated to be:

[0168]

[0169] The control system adjusts the output pressure of the booster pump in the power supply and material supply equipment 33 to 10.9 kPa, until... Approaching ;

[0170] Uniformity determination: Acquire images of the paint layer after spraying and calculate the standard deviation of the grayscale values. Preset threshold ,because To determine if the paint layer is uniform;

[0171] Thickness acceptance criteria: Final paint layer thickness in defect 1 area =48μm, deviation rate Preset threshold ,because The thickness was deemed acceptable.

[0172] Re-spraying path: for the initially detected local thin coating areas, =43 , =14%>5%, generating a spiral spraying path. During the spraying, the moving speed of the second moving frame 3 is reduced to 0.6cm / s, the nozzle flow rate is maintained at 0.575mL / min, the overlap rate between the spraying area and the original spraying area is 35%, and the re-inspection is qualified after the spraying.

[0173] In summary, the present invention allows the gantry frame 1 to be driven by the first lead screw 11 and the auxiliary guide rod 12 on both sides to smoothly extend the first moving frame 2 and the second moving frame 3 into the switch cabinet, accurately matching the height of the space to be sprayed; the multi-directional spraying mechanism 4 includes a top spraying unit 41, an upper and lower spraying unit 42, and a left and right spraying unit 43, all of which can be angled. With the help of multiple nozzles, the top, upper and lower sides, left and right sides of the space to be sprayed in the switch cabinet can be fully coated. Moreover, the detection tool 44 on each unit can simultaneously detect the sprayed area, providing an accurate basis for the spraying operation, ensuring the comprehensiveness and uniformity of the insulating paint coating, and adapting to the special space of the multi-layer drawer type switch cabinet. The operation can be carried out without disassembling the switch cabinet components.

[0174] Image preprocessing effectively eliminates environmental interference through Gaussian filtering, temperature compensation, and light intensity normalization; the Canny edge detection algorithm dynamically determines dual thresholds based on gradient magnitude statistical features and connects edges in combination with gradient direction, enabling complete extraction of defect contours; the multi-feature fusion defect recognition method distinguishes between scratches and stains using parameters such as aspect ratio and perimeter-area ratio, ensuring accurate defect type identification; the three-dimensional physical coordinate mapping model introduces compensation amounts based on moving distance and height, accurately locating the physical position of defects and providing precise positional information for differentiated spraying.

[0175] During dynamic spraying, spraying parameters are adjusted based on the differences in defect types. The output pressure of the power supply and material supply equipment is adjusted in real time through a PID algorithm to offset the deviation in paint layer thickness. Combined with environmental humidity compensation, the nozzle swing angle is adapted to different humidity environments. For quality re-inspection, a paint layer uniformity detection algorithm is used to judge the paint layer status. For unqualified areas, a spiral re-spraying path is used to ensure that the re-sprayed area fully overlaps with the original sprayed area, ultimately achieving uniform and qualified paint layer coverage on the surface to be sprayed.

[0176] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An intelligent insulation detection and multi-nozzle precision spraying device for insulating varnish, comprising a basic support mechanism, a first movable frame (2), and a second movable frame (3), characterized in that: The basic support mechanism is a gantry frame (1). A first lead screw (11) and an auxiliary guide rod (12) are rotatably arranged between the upper and lower ends on both sides of the gantry frame (1). A first connector (13) is screwed onto the first lead screw (11). A second connector (14) is slidably connected to the auxiliary guide rod (12). The first connector (13) and the second connector (14) are both fixedly connected to both sides of the first movable frame (2). A first motor (15) is fixedly connected to the gantry frame (1). The output end of the first motor (15) passes through the gantry frame (1) and is connected to one of the first lead screws (11). The two first lead screws (11) are connected by a first synchronous belt (16). The second movable frame (3) is slidably disposed in the first movable frame (2), and a multi-directional spraying mechanism (4) is provided at the end of the second movable frame (3) away from the gantry (1). The multi-directional spraying mechanism (4) includes a top spraying unit (41), upper and lower spraying units (42), and left and right spraying units (43). Each unit is equipped with a detection tool (44), and each unit can be angled. It also includes a power supply and material supply device (33) installed on the second moving frame (3).

2. The intelligent insulation detection and multi-nozzle insulating varnish precision spraying device according to claim 1, characterized in that: The second moving frame (3) is slidably disposed in the first moving frame (2) by a propulsion mechanism (5). The propulsion mechanism (5) includes sliders (51) fixedly connected to both sides of the second moving frame (3). The sliders (51) are slidably connected to slide rails (52) disposed on both sides of the first moving frame (2). A second lead screw (53) is rotatably connected in the slide rails (52). The second lead screw (53) is screwed into the slider (51). A second motor (54) is fixedly connected to one side of the first moving frame (2). The output end of the second motor (54) passes through the first moving frame (2) and drives one of the second lead screws (53). The two second lead screws (53) are connected by a second synchronous belt (55).

3. The intelligent insulation detection and multi-nozzle insulating varnish precision spraying device according to claim 1, characterized in that: There are multiple top spraying units (41) and left and right end spraying units (43), which are respectively located at the top and left and right sides of the second moving frame (3) away from the gantry (1). The top spraying unit (41) and the left and right end spraying units (43) each include two sets of symmetrically distributed first nozzles (401). The second movable frame (3) is fixedly connected to a first mounting plate (31) and a bidirectional motor (403). The bidirectional motor (403) is located between the first mounting plates (31). The output ends of the bidirectional motor (403) are all driven to connect to a first connecting rod (402). The first connecting rod (402) is rotatably connected to the first mounting plate (31), and the first connecting rod (402) is fixedly connected to a first nozzle (401). The adjacent top spraying units (41) overlap in their spraying coverage areas by rotating. The left and right end spraying units (43) include diagonal areas in their spraying coverage areas by rotating. The detection tool (44) is fixedly connected to the first nozzle (401).

4. The intelligent insulation detection and multi-nozzle insulating varnish precision spraying device according to claim 1, characterized in that: There are multiple upper and lower spraying units (42), which are set on the upper and lower sides of the second moving frame (3) away from the gantry (1). Each unit includes at least one set of second nozzles (404). A third motor (405) and a second mounting plate (32) are fixedly connected to the second moving frame (3). The output end of the third motor (405) is driven to connect to a second connecting rod (406). The second connecting rod (406) is rotatably connected to the second mounting plate (32), and the second nozzle (404) is fixedly connected to the second connecting rod (406). The spraying coverage areas of adjacent upper and lower spraying units (42) overlap due to rotation. The detection tool (44) is fixedly connected to the second nozzle (404).

5. The intelligent insulation detection and multi-nozzle insulating varnish precision spraying device according to claim 1, characterized in that: The inspection tool (44) includes an industrial camera equipped with a fill light, the industrial camera being oriented toward the spraying area.

6. A method for intelligent insulation detection and precise spraying of multi-nozzle insulating varnish, characterized in that: Includes the following steps: S1: Height Adaptation: The control system receives the height parameters of the multi-layer space to be sprayed in the switch cabinet, drives the first motor (15) to move the first moving frame (2) along the first lead screw (11) until the height of the first moving frame (2) matches the space to be sprayed, and locks the position. S2: Defect Detection and Location: S21: Image acquisition: Drive the second motor (54) to make the second moving frame (3) extend into the space to be sprayed at a preset speed. The industrial camera simultaneously acquires the surface image of the insulating part to be sprayed, and the supplementary light dynamically adjusts the brightness according to the ambient light intensity. S22: Image preprocessing: Gaussian filtering for noise reduction, temperature compensation, and light intensity normalization are performed sequentially on the acquired raw image to obtain a standardized image; S23: Defect identification: The Canny edge detection algorithm is used to extract defect contours from the standardized image, and the defect type is identified by contour feature parameters; S24: Physical positioning: Combine the extension distance of the second moving frame (3) and the height position of the first moving frame (2) to establish a mapping model between image coordinates and physical coordinates, and output the three-dimensional physical coordinates of each defect area; S3: Dynamic Precision Spraying S31: Basic parameter configuration: Set the movement speed of the second moving frame (3) Sprayer head reference flow rate Reference swing angle and target paint layer thickness ; S32: Defect Area Parameter Adjustment: Parameters are adjusted differently for different types of defects: the flow rate in the scratch area is adjusted as follows. Movement speed adjusted to The flow rate in the stained area was adjusted to... Movement speed adjusted to ,in This is a correction factor; S33: Real-time closed-loop control: During the spraying process, industrial cameras are used to acquire real-time images of the paint layer and extract paint layer thickness feature values. , with target thickness The comparison yielded the deviation. The output pressure of the power supply and material supply equipment (33) is adjusted by the PID algorithm so that... Approaching Simultaneously, the nozzle oscillation angle is compensated in real time according to the ambient humidity. S4: Quality re-inspection and re-spraying: After the spraying is completed, the second moving frame (3) extends into the space to be sprayed again. The industrial camera collects the paint layer image of the entire area. The paint layer uniformity detection algorithm determines whether there are areas with missed spraying or unqualified thickness. If there are, step S3 is repeated for re-spraying until all areas are qualified.

7. The intelligent insulation detection and multi-nozzle precise spraying method for insulating varnish according to claim 6, characterized in that: In S22, the Gaussian filtering formula is: in, For the original image, Standard deviation Gaussian kernel, This is a convolution operation; The temperature compensation formula is: in, For temperature coefficient, For real-time ambient temperature, Standard temperature; The formula for normalizing light intensity is: in, Standard light intensity, To measure the actual light intensity, This is the preprocessed image.

8. The intelligent insulation detection and multi-nozzle precise spraying method for insulating varnish according to claim 6, characterized in that: In S23, the Canny edge detection algorithm is as follows: Preprocessed image Calculate gradient magnitude and gradient direction Dynamically determine dual thresholds based on the statistical characteristics of gradient magnitude: High threshold: Low threshold: in, The mean of the gradient magnitude. For high threshold coefficients, Low threshold coefficient; After preserving edge details through non-maximum suppression, a gradient-direction-based edge connection strategy is adopted to enhance the connection of weak edges with consistent gradient directions, forming a complete defect profile. Defect type identification is achieved through multi-feature fusion: Set the aspect ratio threshold Perimeter-area ratio threshold When the aspect ratio of the outline And the perimeter area ratio When the aspect ratio of the outline is... And the perimeter area ratio When the time is right, it is judged as a stain defect; among which the aspect ratio threshold is... Perimeter-area ratio threshold Obtained through training with samples; In step S24, the three-dimensional physical coordinate mapping model is as follows: in, The three-dimensional physical coordinates of the defect For image coordinates, This is the scaling factor. This is the initial offset. This is the compensation amount that varies with the extension distance L of the secondary guide rail. For the height of the main rail frame, This is the correction amount in the height direction.

9. The intelligent insulation detection and multi-nozzle precise spraying method for insulating varnish according to claim 6, characterized in that: In S33, the expression for the PID control algorithm is: in, For the booster pump output pressure, For thickness deviation, These are the proportional, integral, and differential coefficients, respectively. The formula for humidity compensation angle is: ,in To compensate for the subsequent swing angle, Humidity coefficient For real-time humidity, This is the standard humidity.

10. The intelligent insulation detection and multi-nozzle precise spraying method for insulating varnish according to claim 6, characterized in that: The paint layer uniformity detection algorithm in S4 includes: Calculate the standard deviation of gray values ​​in the paint layer image. ,when It is judged to be uniform at that time. The preset threshold; Calculate the deviation rate between the paint layer thickness and the target thickness in each area. ,when The thickness was deemed acceptable at that time. This is the deviation threshold; After marking the non-conforming areas, a touch-up spraying path is generated. The touch-up spraying path uses a spiral scanning trajectory to ensure the overlap between the touch-up spraying area and the original spraying area. .

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