Flange numerical control zinc spraying path automatic planning and zinc spraying quantity precision control method and system

Abstract

The application provides a flange plate numerical control zinc spraying path automatic planning and zinc spraying quantity precision control method and system, relates to the technical field of numerical control automation, and the method comprises the following steps: step 1, according to the three-dimensional structure of the flange plate, key areas are identified and divided, the key areas include a groove area, a hole peripheral area and a flat area; step 2, according to the key areas, adaptive spraying paths corresponding to the characteristics of each area are generated; wherein the groove area generates a path along the groove trend; the hole peripheral area generates a bias path around the bolt hole; and the flat area generates an equidistant bias spiral path. The application divides the key areas of the flange plate and generates adaptive spraying paths suitable for each area, establishes a dynamic coupling relationship between the speed of the spray gun and the powder feeding rate, optimizes the parameters in combination with the thickness distribution reference plane and adjusts in real time, can improve the uniformity of the coating, ensures the precision of the zinc spraying quantity, and guarantees the zinc spraying anticorrosion quality of the flange plate.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of numerical control automation, in particular to a flange plate numerical control zinc spraying path automatic planning and zinc spraying amount precise control method and system. BACKGROUND

[0002] In the existing flange plate numerical control zinc spraying technology, the planning of the spraying path may not fully take into account the differences in the geometric features of the workpiece surface. For example, a relatively uniform path strategy is often used, such as a simple reciprocating scanning path, to simplify the programming process. However, this approach may present some challenges when dealing with flange plates with complex structures such as grooves and bolt holes. The adaptability of the path planning to the local geometric features may not be ideal, and the coordination control between the spraying gun moving speed and the powder feeding rate may not be sufficient, which may lead to uneven coating distribution in some cases.

[0003] For example, at the bottom of the groove or around the bolt hole, the coating may be thin or zinc powder may accumulate, thereby affecting the uniformity and consistency of the overall coating. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a flange plate numerical control zinc spraying path automatic planning and zinc spraying amount precise control method and system to ensure that zinc powder is precisely projected only as needed and to reduce the unnecessary accumulation of zinc powder in the hole circumference and groove areas.

[0005] To solve the above technical problems, the technical solution of the present application is as follows:

[0006] In a first aspect, a flange plate numerical control zinc spraying path automatic planning and zinc spraying amount precise control method is provided, which comprises:

[0007] Step 1: identifying and dividing key areas according to the three-dimensional structure of the flange plate, the key areas including a groove area, a hole circumference area, and a flat area;

[0008] Step 2: generating adaptive spraying paths corresponding to the characteristics of each area according to the key areas; for the groove area, generating a path along the groove direction; for the hole circumference area, generating a bias path around the bolt hole; for the flat area, generating a constant pitch reciprocating path;

[0009] Step 3: establishing a dynamic coupling relationship between the spraying gun moving speed and the powder feeding rate according to the adaptive spraying path to obtain dynamic control parameters for maintaining a constant zinc powder projection amount per unit area;

[0010] Step 4: setting one coating thickness measurement point in the groove area, the hole circumference area, and the flat area respectively, and establishing a thickness distribution reference plane according to the spatial positions of the three coating thickness measurement points;

[0011] Step 5, according to the thickness distribution reference plane, calculate the coating uniformity correction coefficient, compensate and adjust the dynamic control parameter, get the optimized dynamic control parameter;

[0012] Step 6, according to the adaptive spraying path and the optimized dynamic control parameter, execute the spraying operation, and in the spraying process, according to the real-time coating thickness data of the thickness distribution reference plane, dynamically adjust the spraying gun path and the spraying zinc amount parameter.

[0013] The second aspect is a flange plate numerical control zinc spraying path automatic planning and zinc spraying amount precise control method and system, comprising:

[0014] The region division module is used for identifying and dividing key regions according to the three-dimensional structure of the flange plate, and the key regions include a groove region, a hole peripheral region and a flat region.

[0015] The path generation module is used for generating adaptive spraying paths corresponding to the characteristics of each region according to the key regions; the groove region generates a path along the groove trend; the hole peripheral region generates a bias path around the bolt hole; and the flat region generates a constant row spacing reciprocating path.

[0016] The parameter generation module is used for establishing a dynamic coupling relationship between the spraying gun moving speed and the powder feeding rate according to the adaptive spraying path, so as to obtain dynamic control parameters for keeping the zinc powder projection amount per unit area constant.

[0017] The plane establishment module is used for setting one coating thickness measurement point in the groove region, the hole peripheral region and the flat region respectively, and establishing a thickness distribution reference plane according to the spatial positions of the three coating thickness measurement points.

[0018] The optimization control module is used for calculating a coating uniformity correction coefficient according to the thickness distribution reference plane, compensating and adjusting the dynamic control parameter, and obtaining an optimized dynamic control parameter.

[0019] The operation execution module is used for executing the spraying operation according to the adaptive spraying path and the optimized dynamic control parameter, and dynamically adjusting the spraying gun path and the spraying zinc amount parameter according to the real-time coating thickness data of the thickness distribution reference plane in the spraying process.

[0020] The third aspect is a computing device, comprising:

[0021] One or more processors;

[0022] A storage device is used for storing one or more programs, when the one or more programs are executed by the one or more processors, so that the one or more processors implement the method.

[0023] In a fourth aspect, a computer readable storage medium having stored therein a program, which when executed by a processor, implements the method.

[0024] The above scheme of the present application at least has the following beneficial effects:

[0025] By key area division and adaptive path generation, the path is planned along the strike for the groove area, the path is offset around the hole for the hole area, and the path is spiral for the flat area, so as to ensure that the spray gun can accurately cover the complex area and avoid missing spraying or repeated spraying; in combination with dynamic coupling of the spray gun speed and the powder feeding rate, the zinc powder projection amount per unit area is kept constant, the coating unevenness problem is solved from the path adaptation and parameter coordination, the coating thickness consistency is improved, and local protection deficiency or material waste is avoided; by establishing a three-dimensional thickness monitoring reference plane through the thickness distribution reference plane, the control parameters are optimized in combination with the uniformity correction coefficient, the path and the zinc spraying amount are adjusted in real time during the spraying process, when the thickness deviation of a certain area is monitored to be out of range, the spray gun parameters or the local path can be corrected in time, without waiting for the spraying to be completed for remediation, so as to reduce the rework rate caused by unqualified coating, and improve the process stability and production efficiency; through dynamic coupling control and real-time parameter optimization, it is ensured that the zinc powder is accurately projected according to the demand, and the redundant accumulation in the hole and groove areas is reduced; at the same time, real-time path correction avoids repeated spraying caused by deviation, further reduces the zinc powder consumption, improves the material utilization rate, and indirectly reduces the production cost; through accurate control of the whole process, the coating thickness of each area of the flange plate, especially the groove and hole area which are prone to problems, is up to standard and uniform, and premature rust and wear caused by local thin coating is avoided; in combination with uniform zinc layer protection, the equipment maintenance frequency is reduced, and the operation reliability of the industrial equipment is improved. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 FIG. 1 is a flowchart of a path automatic planning and zinc spraying amount accurate control method of a flange plate numerical control zinc spraying provided by an embodiment of the present application.

[0027] Figure 2 FIG. 2 is a schematic diagram of a path automatic planning and zinc spraying amount accurate control system of a flange plate numerical control zinc spraying provided by an embodiment of the present application. DETAILED DESCRIPTION

[0028] Exemplary embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings; however, they are not limited to the embodiments set forth herein but can be implemented in various forms. The embodiments are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those skilled in the art.

[0029] As Figure 1As shown, the embodiment of the present application proposes a flange plate numerical control zinc spraying path automatic planning and zinc spraying quantity precise control method, the method comprises the following steps:

[0030] Step 1, according to the three-dimensional structure of the flange plate, the key area is identified and divided, the key area includes the groove area, the hole area and the flat area;

[0031] Step 2, according to the key area, the adaptive spraying path corresponding to the characteristics of each area is generated; wherein the groove area, the path along the groove direction is generated; the hole area, the offset path around the bolt hole is generated; the flat area, the constant row distance reciprocating path is generated;

[0032] Step 3, according to the adaptive spraying path, the dynamic coupling relationship between the spraying gun moving speed and the powder feeding rate is established, and the dynamic control parameter for keeping the zinc powder projection quantity per unit area constant is obtained;

[0033] Step 4, a coating thickness measuring point is set in the groove area, the hole area and the flat area respectively, and a thickness distribution reference plane is established according to the spatial positions of the three coating thickness measuring points;

[0034] Step 5, according to the thickness distribution reference plane, the coating uniformity correction coefficient is calculated, the dynamic control parameter is compensated and adjusted, and the optimized dynamic control parameter is obtained;

[0035] Step 6, according to the adaptive spraying path and the optimized dynamic control parameter, the spraying operation is executed, and in the spraying process, according to the real-time coating thickness data of the thickness distribution reference plane, the spraying gun path and the zinc spraying quantity parameters are dynamically adjusted.

[0036] In the embodiment of the present application, by key area division and adaptive path generation, the path is planned along the strike for the groove area, the path is offset around the hole for the hole area, and the path is spiral for the flat area, so as to ensure that the spray gun can accurately cover the complex area and avoid missing or repeated spraying; in combination with dynamic coupling of the spray gun speed and the powder feeding rate, the zinc powder projection amount per unit area is kept constant, the coating unevenness problem is solved from the path adaptation and parameter coordination, the coating thickness consistency is improved, and local insufficient protection or material waste is avoided; by establishing a three-dimensional thickness monitoring reference plane through the thickness distribution reference plane, the control parameters are optimized in combination with the uniformity correction coefficient, the path and the zinc projection amount are adjusted in real time during the spraying process, when the thickness deviation of a certain area is monitored to be out of range, the spray gun parameters or the local path can be corrected in time, without waiting for the spraying to be completed for remediation, so as to reduce the rework rate caused by unqualified coating, improve the process stability and production efficiency; through dynamic coupling control and real-time parameter optimization, it is ensured that the zinc powder is accurately projected according to the demand, and the redundant accumulation in the hole and groove areas is reduced; at the same time, real-time path correction avoids repeated spraying caused by deviation, further reduces the zinc powder loss, improves the material utilization rate, and indirectly reduces the production cost; through accurate control of the whole process, the coating thickness of each area of the flange plate, especially the groove and hole area which are prone to problems, is up to standard and uniform, so as to avoid premature rust and wear caused by local thin coating; in combination with uniform zinc layer protection, the equipment maintenance frequency is reduced, and the operation reliability of the industrial equipment is improved.

[0037] In a preferred embodiment of the present application, step 1 comprises:

[0038] Step 100, according to the geometric feature parameters in the three-dimensional structure of the flange plate, the sealing groove and the stop region are identified, and the sealing groove and the stop region are divided into groove area; according to the hole array distribution characteristics in the three-dimensional structure of the flange plate, the peripheral annular region of the bolt hole is divided into hole peripheral area; the continuous planar region of the flange plate surface except the groove area and the hole peripheral area is divided into flat area, which specifically includes: first, the three-dimensional point cloud data of the flange plate is collected by a three-dimensional scanning device (such as a laser scanner), and the geometric feature parameters of the flange plate surface are extracted therefrom, including but not limited to the groove width, groove depth, groove length of the sealing groove, the step height, the step width of the stop, the hole diameter, the hole coordinate, the arrangement rule of the hole array, such as the center distance, the distribution angle when the circumferential distribution, the row spacing, the column spacing when the matrix distribution, and the flatness parameters of the whole flange plate surface; wherein the preset specification range of the sealing groove is groove width 5-20mm, groove depth 2-8mm, the preset specification of the stop is step height 3-10mm, step width 5-15mm, the recess structure with groove width in the range of 5-20mm, groove depth in the range of 2-8mm (satisfying the sealing function design requirement), groove length extending along the flange plate circumference or radial direction is identified as the sealing groove; the annular or block-shaped protruding structure with 3-10mm step height, 5-15mm step width, used for flange plate butt joint positioning is identified as the stop region; the identified sealing groove and stop region are collectively divided into groove area, and the groove area range is determined by fitting the curved boundary when dividing, that is, a preset minimum coverage allowance is extended outward along the edge of the sealing groove and the stop region, the allowance is determined according to the effective spraying range of the spray gun, and the value is 1-3mm, forming the closed boundary of the groove area; based on the hole array distribution characteristics in the three-dimensional structure of the flange plate, the edge point cloud data of the bolt hole is fitted by Hough transform algorithm, and the hole diameter and hole center coordinate of each bolt hole are determined; according to the protection requirement of the bolt hole, the minimum coverage distance (taking the value of 0.5-2mm, ensuring that the edge of the bolt hole is completely covered) and the annular width (taking the value of 3-8mm, ensuring that a certain range of area around the hole is covered) of the annular region around the hole are set, the range of the hole peripheral area is determined by the following calculation, the inner radius of the hole peripheral area is calculated , the calculation method is to add the minimum coverage distance to the bolt hole radius (half of the hole diameter ), and the formula is ; the outer radius of the hole peripheral area is calculated , the calculation method is to add the annular width to the inner radius , and the formula is ; taking the center coordinate of each bolt hole as the center, in the plane parallel to the flange plate surface, the and To form a ring-shaped region at the boundary, the ring-shaped regions corresponding to all bolt holes are uniformly divided into the periphery region. Flat areas are identified and divided, and a global surface analysis is performed on the flange surface. First, a region clipping algorithm is called to remove the regions already divided into groove and periphery regions from the flange's 3D point cloud data, resulting in a point cloud subset containing only the remaining area to be analyzed. Then, planar features are extracted from this point cloud subset, specifically by calculating the angle between the normal vectors of any two adjacent points within the remaining area. The calculation process is as follows: First, from the point cloud subset, a target point is selected based on a preset neighborhood search radius (0.5-2mm, the radius is determined according to the point cloud data density; the higher the point cloud density, the smaller the radius, ensuring sufficient coverage of points around the target point to fit a stable local plane). Search using the K-nearest neighbor search algorithm or the radius search algorithm All points within the neighborhood form the neighborhood point set. ( The number of interior points must meet the plane fitting accuracy requirements, including at least 3 non-collinear points; then select... Points whose spatial distance is ≤ 2 times the neighborhood search radius are considered as neighboring points. Obtain using the same search method neighborhood point set This establishes the pair of adjacent points for the angle between the normal vectors to be calculated. and the corresponding neighborhood point set , The second step is to... neighborhood point set The local plane is fitted using the least squares method; specifically, the general equation of the local plane is constructed. (in Not both zero, vector (where the plane is a normal vector), Coordinates of each point ( for The indentation of the interior point for Substituting the number of interior points into the equation, we form m linear equations; the error function is defined as the sum of the squared distances from all points to the plane, and the distance is calculated as follows: The plane coefficients that minimize the error function are obtained by using the least squares method. ,get Normal vector of the local plane Using the same method to neighborhood point set By fitting a local plane, the plane coefficients can be obtained. ,get Normal vector of the local plane ; third step, calculating the included angle of the normal vector, first normalizing the normal vector , then calculating the dot product of the normalized normal vector and the vector , the calculation method is as follows: the x component of the vector is multiplied by the x component of the vector , and the y component of the vector is multiplied by the y component of the vector , and the z component of the vector is multiplied by the z component of the vector , the formula is , the dot product result is obtained ; finally, the included angle is calculated by the inverse cosine function, the formula is , and the angle is converted into an angle value (unit: degree), if the included angle calculated above is less than a preset flatness threshold (the threshold is determined according to the flatness design requirement of the flange plate surface, and the value is ≤0.1°), it is determined that the local area where the vector and the vector are located is a continuous plane; all adjacent point pairs in the point cloud subset are traversed according to the above method, and all areas determined as continuous planes are integrated to form a flat area without obvious concave and convex parts; finally, the boundary discrete points of the flat area are fitted by a B-spline curve to determine the closed boundary of the flat area, so that the flat area is completely covered without overlapping with the groove area and the hole area, and the remaining surface of the flange plate is completely covered.

[0039] In this embodiment, by accurately identifying the sealing groove and the stop opening and dividing them into the groove area, and identifying the bolt hole array and dividing it into the hole area, the range of different structural feature areas on the surface of the flange plate is determined, and the problem of insufficient coverage caused by one-size-fits-all for complex areas is avoided; the remaining continuous plane is divided into a flat area, which realizes the fine division of the surface of the flange plate, reduces defects such as thin coating in the groove area and zinc powder accumulation in the hole area in the subsequent spraying process, improves the uniformity and consistency of the coating from the source, and the clear division also provides a regional basis for the targeted adjustment of the subsequent dynamic control parameters (such as the speed of the spray gun and the powder feeding rate), avoiding the problem of insufficient local adaptability caused by uniform parameter setting.

[0040] In a preferred embodiment of the present application, the step 2 comprises:

[0041] Step 200, according to the three-dimensional profile data of the groove area, the groove center line is extracted, and the adaptive spraying path parallel to the groove direction is generated based on the groove center line, specifically including: for the divided groove area, the full section three-dimensional profile data of the groove area along its direction is intercepted from the flange three-dimensional point cloud data, which contains the discrete point coordinates (xi, yi, zi) (i = 1, 2,..., n, n is the number of discrete points) of the inner wall (two side walls and groove bottom) of the groove, and the density of the discrete points meets the profile accuracy requirement (ensuring that the bending and turning characteristics of the groove can be accurately reflected); along the groove direction, the groove is divided into several equally spaced cross sections (the cross section direction is perpendicular to the groove direction), and the following calculations are performed for each cross section: first, the average value x of the x coordinates of all inner wall discrete points in the section is calculated, second, the average value y of the y coordinates of all inner wall discrete points in the section is calculated, then the groove depth h is determined, and the calculation method is to subtract the z coordinate of the groove bottom from the z coordinate of the groove top; finally, the z coordinate z of the center of the section is calculated, and the calculation method is to add half of the groove depth h to the z coordinate of the groove bottom, thereby obtaining the center coordinates (x, y, z) of each cross section; arrange the center coordinates of all cross sections in order along the groove direction, and use the cubic spline interpolation algorithm to fit these center coordinates to obtain a smooth and continuous groove center line. During the fitting process, it is ensured that the curvature change of the center line is consistent with the groove direction and there is no obvious inflection point.

[0042] The effective spraying width W of the spray gun is obtained (determined by the spray gun model, spraying pressure and other parameters), the path overlap rate k is set (the value is 0.3-0.7, which ensures that there is no missed spraying in the adjacent path spraying area), the path spacing s is calculated, and the calculation method is to multiply the effective spraying width W of the spray gun by the path overlap rate k; taking the groove center line as the reference path, offset the path spacing s to both sides of the groove in the direction perpendicular to the groove center line, and generate the first path parallel to the center line; repeat the offset process until all the generated parallel paths can completely cover the closed boundary of the groove area, that is, the distance of the outermost path beyond the groove area boundary is not less than the product of the effective spraying width W of the spray gun and (1 minus the path overlap rate k) divided by 2, and all the generated parallel paths together constitute the adaptive spraying path of the groove area.

[0043] Step 201: Determine the center coordinates of the bolt holes based on the bolt hole position parameters in the periphery area. Generate an adaptive spraying path around the bolt holes with a set offset distance based on the center coordinates. Specifically, this includes: using the bolt hole edge discrete point data obtained in step 100, fitting the circular contour of the bolt holes using the least squares method. The specific process is as follows: Let the coordinates of the bolt hole edge discrete points be (xi, yi, zi) (i=1, 2, ..., n). Since the bolt holes are perpendicular to the flange surface, the z-coordinates of all edge discrete points of the same bolt hole are approximately equal. First, calculate the z-coordinate z-hole of the plane where the bolt hole is located. The calculation method is to add the z-coordinates (z1, z2 up to zn) of all edge discrete points and then divide by the number of discrete points n. In the xy plane, assume the center coordinates of the bolt hole are (x0, y0) and the radius is r, which is half of the bolt hole diameter determined in step 100. Establish a fitting equation. By minimizing the error function (the error function is the sum of all discrete points) The sum of the squares of the differences), solve for the center coordinates (x0, y0), combine with the z coordinate of the plane where the bolt hole is located (z_hole), and obtain the center coordinates of the bolt hole (x0, y0, z_hole); according to the bolt hole diameter r, that is, the bolt hole diameter determined in step 100 and the protection requirements of the hole periphery, set the offset distance b around the bolt hole (to ensure that the distance between the path and the edge of the bolt hole meets the spraying coverage requirements and avoids zinc powder accumulation), then the radius R1 of the first surrounding path = bolt hole radius r + b, and the value is 0.3-1.5mm. This range can ensure that the path maintains a reasonable distance from the edge of the bolt hole, which meets the spraying coverage requirements and avoids zinc powder accumulation at the edge of the hole; with the bolt hole center coordinates (x0, y0, z_hole) as the center, generate a circular path with radius R1 in the plane z = z_hole; if the annular width of the hole periphery ( - If the width of the spray gun is greater than the effective spray width W, then calculate the number of required wraparound paths. ,in For path spacing, k is the overlap ratio, ranging from 0.3 to 0.7. This range avoids gaps between adjacent paths that could lead to missed spraying, while also preventing excessive overlap that could cause zinc powder buildup and material waste. ceil is the rounding-up function. Starting from the radius R1 of the first circular path, a concentric circular path is generated for each outward offset of path spacing s. The radius of the i-th path (i=1, 2, ..., N) is... = + until the radius of the outermost path All the generated concentric circular paths together constitute the adaptive spraying path for the periphery area.

[0044] In step 202, the path starting point is determined according to the boundary profile characteristics of the flat area, and the adaptive spraying path with constant row spacing is generated based on the path starting point, specifically including: for the divided flat area, from the flat area point cloud subset in the flange three-dimensional point cloud data, the subset is the remaining area after the groove area and the hole peripheral area are removed, the Canny edge detection algorithm is used to extract the boundary discrete points, that is, by setting the gradient threshold (the high threshold value is 200-300, which is used to filter the clear boundary points with significant gray scale change, so as to avoid misjudging the noise as the boundary; the low threshold value is 50-100, which is used to connect the weak boundary points with weak gray scale change, so as to ensure the boundary continuity), the gray scale difference between the flat area and the surrounding area is highlighted, the extracted boundary discrete points are continuous and non-redundant, and the edge profile of the flat area is fully reflected; the extracted boundary discrete points are taken as the fitting object, the B-spline curve fitting algorithm is used for curve reconstruction, the number of spline nodes is adjusted (the number of nodes is determined according to the density of the boundary discrete points, so as to ensure that 1 node corresponds to 10-20 discrete points), the fitting curve is smoothly transitioned, and finally the closed boundary profile of the flat area without breakpoints and overlap is obtained, and the profile keeps a preset interval (not less than 1 / 2 of the effective spraying width of the spray gun) with the closed boundary of the groove area and the hole peripheral area, so as to avoid the confusion of the area boundary.

[0045] According to the shape characteristics of the flat area, a path starting point S (xS, yS, zS) is selected on the closed boundary contour. If the flat area is circular (such as a flange disc), the pre-stored center coordinates of the flange disc (xheart, yheart, zheart) are called first, the spatial distance of each point on the boundary contour from the center of the flange disc is calculated, and the point with the smallest distance is selected as the starting point S, which is close to the center of the flat area. If the flat area is square or irregular, a fixed reference line is determined first, such as the radial line of the flange disc, which is defined as a ray pointing from the center of the flange disc to the edge of the flat area. The perpendicular distance of each vertex and discrete point on the boundary contour to the reference line is calculated (the perpendicular distance is calculated based on the two-dimensional plane projection to ensure adaptation to the direction of the path). The point with the smallest distance is selected as the starting point S. Regardless of the shape, the starting point S must satisfy the condition that the distance to the boundary of the groove area and the hole area is not less than 1 / 2 of the effective spraying width W of the spray gun to avoid covering the non-flat area when starting spraying and to ensure smooth starting spraying. According to the effective spraying width W of the spray gun (determined by the spray gun model, spraying pressure, etc.) and the path overlap rate k, which is 0.3-0.7, this range can ensure effective overlap of adjacent path spraying areas to avoid missed spraying, while preventing excessive overlap from causing waste of zinc powder. The path spacing is calculated by path spacing = effective spraying width W of the spray gun x path overlap rate k. Then the path reference direction of the flat area is determined. The radial direction of the circular flat area is preferred (the path radiates towards the edge to reduce curve turning to improve spraying smoothness). The direction parallel to one pair of opposite sides of the square flat area is selected (to reduce the number of path starts and stops to reduce coating thickness fluctuations). The direction along the longest axis of the irregularly shaped flat area is selected (to maximize the length of a single path and improve spraying efficiency). From the starting point S, the first path is generated along the path reference direction, with the starting end being S and the end extending to the opposite boundary of the flat area along the reference direction to ensure that the path length completely covers the entire length of the flat area (from one boundary to the other boundary) without any local uncovered area. When the first path reaches the boundary of the flat area, the spray gun is controlled to offset the path spacing in a direction perpendicular to the reference direction to generate the second path, and the direction of the second path is opposite to that of the first path, such as from left to right for the first path and from right to left for the second path, to avoid coating thickness fluctuations caused by frequent starting and stopping of the spray gun and to ensure smooth path connection. The above offset-generation process is repeated to generate the third, fourth,..., nth paths in turn until all paths cover the closed boundary contour of the flat area. During the process, the distance of the outermost path from the boundary of the flat area is determined in real time to ensure that the distance of the outermost path beyond the boundary of the flat area is not less than the effective spraying width of the spray gun , which can compensate for the problem of spraying intensity decay at the edge of the spray gun and avoid missed spraying at the edge of the flat area. The finally generated all paths have no overlap and no omission, and together constitute the adaptive spraying path of the flat area.

[0046] In this embodiment, the path parallel to the groove center line is generated based on the groove center line, which ensures that the path fits the bending and turning features of the groove, fully covers the deep part and both sidewalls of the groove, and avoids the easy-to-occur missed spraying or uneven coverage of the path in the groove area; the offset path around the hole is generated based on the hole center, which ensures that the path fits the annular features of the hole peripheral area, uniformly covers the edge and peripheral area of the bolt hole, and avoids the easy-to-occur edge missed spraying or center accumulation of the path in the hole peripheral area; the constant pitch path is generated based on the boundary of the flat area, which reduces the start-stop times of the reciprocating scanning path, reduces the coating overlap error at the path junction, and ensures the uniformity of the coating on the flat area.

[0047] In a preferred embodiment of the present application, the step 3 comprises:

[0048] In step 300, the curvature feature of the adaptive spraying path is extracted, and the spraying gun moving speed reference value is calculated according to the curvature feature, specifically including: discretizing the adaptive spraying path, which covers the groove area, the hole peripheral area, and the flat area, into a plurality of continuous path points at a preset interval, the preset interval is 0.5-2mm (adjust according to the complexity of the path, 0.5-1mm at the bending part to accurately capture the bending feature, and 1-2mm at the gentle part to balance the efficiency), to ensure that the interval between adjacent path points can accurately reflect the bending degree of the path; for each path point, the previous adjacent path point (previous point) and the next adjacent path point (next point) are selected to form a three-point combination of the previous point-current point-next point; the first tangent direction of the line connecting the previous point and the current point is calculated, that is, the x-direction distance (current point x coordinate minus previous point x coordinate) and the y-direction distance (current point y coordinate minus previous point y coordinate) from the previous point to the current point are calculated first to determine the direction vector of the first tangent direction; similarly, the x-direction distance and the y-direction distance from the current point to the next point are calculated to determine the direction vector of the second tangent direction; the included angle between the two tangent directions is calculated by a trigonometric function, that is, the dot product of the two direction vectors (the product of the x component of the first vector and the x component of the second vector, plus the product of the y component of the first vector and the y component of the second vector) is calculated first, then the modulus of the two direction vectors (the square root of the sum of the squares of the components) is calculated, and the dot product is divided by the product of the two moduli to obtain the cosine value of the included angle, and the included angle is obtained by the inverse cosine function; the arc length of the previous point to the current point to the next point is measured, which is calculated by first calculating the straight line distance from the previous point to the current point (the square root of the sum of the squares of the x-direction distance and the y-direction distance), and then calculating the straight line distance from the current point to the next point, and the sum of the two is the arc length; the path curvature at the current path point is obtained by dividing the included angle (radian) of the two tangent directions by the arc length, the greater the curvature value, the more obvious the path bending, and the curvature feature extraction of the entire adaptive spraying path is completed by traversing all path points, forming the curvature distribution data.

[0049] The calculation of the spray gun movement speed reference value first presets the maximum threshold and the minimum threshold of the spray gun movement speed, which is determined according to the spray gun performance and the zinc powder atomization effect, the maximum threshold is 200-300 mm / s, and the minimum threshold is 50-100 mm / s, so as to ensure that the zinc powder can be stably attached when the speed is in this range; according to the adaptation rule of path curvature and speed (the greater the curvature, the more obvious the path bending, the speed needs to be reduced to avoid zinc powder accumulation; the smaller the curvature, the flatter the path, and the speed can be increased to improve the efficiency), a corresponding relationship between the curvature and the speed adjustment amount is established, the speed adjustment amount = preset speed adjustment coefficient x curvature value, wherein the preset speed adjustment coefficient is 0.1-0.3; the reference speed of the flat section of the path is set, that is, the initial speed when the curvature is 0, the reference speed is 150-200 mm / s, the speed reference value of the current path point = flat section reference speed - speed adjustment amount, if the calculated speed reference value is lower than the minimum threshold (50-100 mm / s), the minimum threshold is taken as the speed reference value of the point, if it is higher than the maximum threshold (200-300 mm / s), the maximum threshold is taken as the speed reference value of the point, all path points are traversed, and the spray gun movement speed reference value corresponding to each path point is obtained.

[0050] In step 301, according to the spray gun movement speed reference value and the constant condition of unit area zinc powder projection amount, a dynamic coupling relationship between the spray gun movement speed and the powder feeding rate is established, which specifically includes: the unit area zinc powder projection amount refers to the mass of the zinc powder attached on the unit area of the flange plate after spraying, according to the corrosion prevention requirement of the flange plate, the value is preset as a fixed value, which is 5.5-8.5 g / m 2 in ordinary industrial environment, 8.5-11.5 g / m 2 in moderate corrosive environment such as chemical industry and humidity, and 11.5-14.5 g / m 2, namely constant conditions, to ensure that the coating thickness meets the design standards; determine the correlation formula of the powder feeding rate and the spray gun speed, the first step is to determine the total amount of powder feeding in unit time, that is, the total mass of zinc powder sprayed by the spray gun in unit time (total amount of powder feeding) = powder feeding rate (the mass of zinc powder delivered by the powder feeding device in unit time) x spraying time; the second step is to determine the spraying area in unit time, that is, the flange plate area sprayed by the spray gun in unit time (spraying area) = spray gun moving speed (the distance moved by the spray gun in unit time) x effective spraying width of the spray gun (the transverse width covered by the zinc powder sprayed by the spray gun, which is determined by the model of the spray gun and the spraying pressure); the third step is to substitute the expressions of the total amount of powder feeding and the spraying area into the expression of the constant condition of the zinc powder projection amount per unit area (zinc powder projection amount per unit area = total amount of powder feeding ÷ spraying area) to obtain zinc powder projection amount per unit area = (powder feeding rate x spraying time) ÷ (spray gun moving speed x effective spraying width of the spray gun x spraying time); in the formula, the spraying time can be cancelled out, and finally the powder feeding rate = zinc powder projection amount per unit area x spray gun moving speed x effective spraying width of the spray gun is determined, which is the dynamic coupling relationship between the spray gun moving speed and the powder feeding rate, indicating that when the zinc powder projection amount per unit area and the effective spraying width of the spray gun are fixed, the powder feeding rate needs to be changed in proportion to the spray gun moving speed.

[0051] At step 302, the nozzle moving speed reference value and the powder feeding rate set value are adjusted according to the dynamic coupling relationship and the change of the curvature characteristic, an adjustment result is obtained, and a dynamic control parameter for keeping the unit area zinc powder projection amount constant is generated according to the adjustment result, which specifically comprises: real-time acquisition of the path curvature distribution data extracted in step 300, calculation of the curvature of the current path point and the curvature change amount of the previous path point, the curvature change amount = the absolute value of the difference between the curvature of the current path point and the curvature of the previous path point; the preset curvature change threshold value is 0.05-0.1 rad / mm (determined according to the uniformity requirement of the coating, to avoid frequent adjustment of the parameter due to slight fluctuation of the curvature), if the curvature change amount exceeds the threshold value, the nozzle moving speed reference value and the powder feeding rate set value need to be adjusted; the preset speed adjustment increment is 10-20 mm / s, if the curvature of the current path point is greater than the curvature of the previous path point (the degree of path bending increases), the adjusted speed of the current path point = the speed reference value of the previous path point - the speed adjustment increment, if the curvature of the current path point is less than the curvature of the previous path point (the degree of path bending decreases), the adjusted speed of the current path point = the speed reference value of the previous path point + the speed adjustment increment; after adjustment, it is needed to check whether the speed is within the range of the maximum threshold value (200-300 mm / s) and the minimum threshold value (50-100 mm / s) preset in step 300, if it exceeds, the corresponding threshold value is taken as the adjusted speed; according to the dynamic coupling relationship (powder feeding rate = unit area zinc powder projection amount x nozzle moving speed x effective spraying width of the nozzle) of the nozzle moving speed and the powder feeding rate established in step 301, the adjusted nozzle moving speed of the current path point is substituted into the coupling relationship, and the powder feeding rate adjustment value of the current path point is calculated to ensure that the powder feeding rate and the adjusted nozzle moving speed keep a proportional relationship and meet the condition of constant unit area zinc powder projection amount; the adjusted nozzle moving speed of each path point and the corresponding powder feeding rate adjustment value are arranged into a parameter group, each parameter group contains the path point position, the adjusted nozzle moving speed and the adjusted powder feeding rate, and all parameter groups jointly constitute the dynamic control parameter for keeping the unit area zinc powder projection amount constant.

[0052] In this embodiment, the nozzle speed is adapted according to the path curvature, which avoids zinc powder accumulation or thinning caused by uniform speed in curved paths such as turning places of groove areas and annular paths around holes; through the dynamic coupling relationship, the powder feeding rate and the speed are changed synchronously, the unit area zinc powder projection amount is strictly kept constant, the coating thickness fluctuation caused by unsynchronized adjustment of the powder feeding rate when the speed changes is avoided, the consistency of the coating thickness in different areas is ensured from the parameter control level, and the coating defects in complex areas such as groove areas and hole surrounding areas are reduced.

[0053] In a preferred embodiment of the present application, the step 4 comprises:

[0054] Step 400, setting the first coating thickness measurement point at the center of the groove area, the second coating thickness measurement point at the center of the annular band of the hole perimeter area, and the third coating thickness measurement point at the center of the flat area, specifically including: along the length direction of the groove, measuring the total length of the groove (the distance from one end of the groove to the other end), and the midpoint length position is obtained by dividing the total length by 2; along the depth direction of the groove, measuring the distance from the top of the groove to the bottom of the groove (the groove depth), and the midpoint depth position is obtained by dividing the groove depth by 2; along the width direction of the groove, measuring the distance between the two side walls of the groove (the groove width), and the midpoint width position is obtained by dividing the groove width by 2; the intersection point of the three direction midpoints is the center of the groove area, and the first coating thickness measurement point is set at this point.

[0055] The hole perimeter area is an annular area with the bolt hole as the center, and the inner radius and outer radius of the annular band have been determined in step 100; the annular band width = outer radius - inner radius; the center radius = inner radius + (annular band width ÷ 2); a point on the center line of the annular band is determined in the direction of the center radius (arbitrary direction) with the bolt hole center as the center (the point needs to avoid the bolt hole and be within the hole perimeter area), and the second coating thickness measurement point is set at this point.

[0056] The longest distance (the longest axis length) and the shortest distance (the shortest axis length) of the closed boundary contour of the flat area are measured with a measuring tool, and the longest axis (a straight line connecting the two points farthest apart on the contour) and the shortest axis (a straight line connecting the two points closest on the contour and perpendicular to the longest axis) are found; the intersection of the two axes is the geometric center of the flat area, and if the flat area is a regular shape, the geometric center of a circle is the center of the circle, and the geometric center of a square is the intersection of the two diagonals; the third coating thickness measurement point is set at the geometric center.

[0057] Step 401: Establish a thickness distribution reference plane based on the spatial coordinates of the first, second, and third coating thickness measurement points. This specifically includes: measuring the spatial coordinates of the first, second, and third coating thickness measurement points using a three-dimensional positioning device, such as a laser positioning instrument, to obtain the x-coordinate, y-coordinate, and z-coordinate values ​​of each measurement point, denoted as the first measurement point coordinates, second measurement point coordinates, and third measurement point coordinates; establishing the thickness distribution reference plane using the three-point planar principle. Firstly, using the first measurement point as the reference point, calculate the coordinate difference between the second and first measurement points (second measurement point x-coordinate - first measurement point x-coordinate, second measurement point y-coordinate - first measurement point y-coordinate, second measurement point z-coordinate - first measurement point z-coordinate, all in mm), forming a first vector; similarly, calculate the coordinate difference between the third and first measurement points (third measurement point x-coordinate - first measurement point x-coordinate, second measurement point y-coordinate - first measurement point y-coordinate, second measurement point z-coordinate - first measurement point z-coordinate, all in mm), forming a first vector; similarly, calculate the coordinate difference between the third and first measurement points (third measurement point x-coordinate - first measurement point z-coordinate, all in mm). The first step involves using the coordinates of the first and second measurement points (x-coordinate of the first measurement point, y-coordinate of the third measurement point, z-coordinate of the third measurement point, and z-coordinate of the first measurement point, all in mm) to form a second vector. The second step involves performing a cross product on the first and second vectors to obtain the normal vector of the thickness distribution reference plane (in mm). The normal vector's x-component is calculated as: x = (y-component of the first vector × z-component of the second vector) - (z-component of the first vector × y-component of the second vector); y-component is calculated as: y = (z-component of the first vector × x-component of the second vector) - (x-component of the first vector × z-component of the second vector); z-component is calculated as: z = (x-component of the first vector × y-component of the second vector) - (y-component of the first vector × x-component of the second vector). The third step involves substituting the x, y, and z components of the normal vector, along with the x, y, and z coordinates of the first measurement point (all in mm), into the general equation of the plane. The expression for the general equation of the plane is: ,in , , These are the x, y, and z components of the normal vector to the thickness distribution reference plane, respectively. , , Let the spatial coordinates be any point on the thickness distribution reference plane. , , Determine the spatial coordinates of the first coating thickness measurement point (the center measurement point of the trench area). , , and , , After obtaining the specific values, the plane corresponding to this equation becomes the thickness distribution reference plane.

[0058] In this embodiment, the three measuring points are respectively located at the center positions of the groove area, the hole peripheral area and the flat area, which can reflect the coating thickness conditions of each core area, and avoid the local thickness omission caused by random point monitoring, such as the problem that the center of the groove area is prone to be thin and the center of the hole peripheral area is prone to be accumulated, which cannot be effectively monitored; the thickness distribution reference plane is established based on the spatial coordinates of the three key measuring points, which can be used as the reference plane of the coating thickness distribution of the entire flange plate surface, can quickly judge the coating uniformity, and avoid the correction deviation caused by no reference, and further guarantee the overall uniformity of the coating.

[0059] In a preferred embodiment of the present application, the step 5 comprises:

[0060] In step 500, the real-time coating thickness data of the three coating thickness measuring points is analyzed according to the thickness distribution reference plane, and the difference between the target thickness is obtained to obtain the coating uniformity evaluation index, specifically comprising: according to the anti-corrosion design requirement of the flange plate, the target thickness of the coating is preset, the value is 80-200 μm, which is a fixed value, and the value is specifically determined according to the corrosion grade of the flange plate use environment, such as 150-200 μm for marine corrosion environment, 80-120 μm for ordinary atmospheric corrosion environment, to ensure that the anti-corrosion performance standard is met; the real-time coating thickness data of the first coating thickness measuring point (the center of the groove area), the second coating thickness measuring point (the center of the hole peripheral area ring) and the third coating thickness measuring point (the center of the flat area) is collected by a thickness detection device such as a laser thickness gauge, and is recorded as the real-time thickness value of the three measuring points; for each measuring point, the difference between the real-time thickness value and the target thickness is calculated, that is, the first measuring point thickness difference = the first measuring point real-time thickness value-target thickness; the second measuring point thickness difference = the second measuring point real-time thickness value-target thickness; the third measuring point thickness difference = the third measuring point real-time thickness value-target thickness; the thickness difference data of the three measuring points is obtained (the difference is a positive value indicating that the thickness of the point exceeds the target value, and a negative value indicating that the thickness of the point is lower than the target value); the thickness difference average value and the thickness difference standard deviation are selected as the coating uniformity evaluation index, specifically, the thickness difference of the three measuring points is added, and then divided by 3, that is, the thickness difference average value = (the first measuring point thickness difference + the second measuring point thickness difference + the third measuring point thickness difference) ÷ 3; the index reflects the deviation trend of the overall thickness and the target thickness; the difference between the thickness difference of each measuring point and the thickness difference average value is calculated, then each difference is squared, then the three square values are added and divided by 3 to obtain the average value of the square sum, and finally the average value is squared to obtain the thickness difference standard deviation, which reflects the thickness dispersion degree between the three measuring points, the larger the value, the worse the coating uniformity.

[0061] Step 501, according to the comparison between the coating uniformity evaluation index and the preset uniformity threshold, the coating uniformity correction coefficient is calculated, specifically including: according to the flange coating uniformity design requirement (combined with the corrosion prevention demand of flange containing groove, bolt hole and other complex structure), the average value threshold of thickness difference and the standard deviation threshold of thickness difference (both thresholds are fixed values, to ensure that the coating uniformity meets the industry standard) are preset; wherein, the average value threshold of thickness difference is divided according to the use environment, the value of ordinary industrial environment is 10-15 μm, the value of moderate corrosion environment is 15-20 μm, and the value of strong corrosion environment is 20-25 μm; the standard deviation threshold of thickness difference is divided, the value of ordinary industrial environment is 8-12 μm, the value of moderate corrosion environment is 12-16 μm, and the value of strong corrosion environment is 16-20 μm; the average value of thickness difference obtained in step 500 is compared with the preset average value threshold of thickness difference, and the standard deviation of thickness difference is compared with the preset standard deviation threshold of thickness difference, to determine whether the correction coefficient needs to be calculated, if the average value of thickness difference exceeds the average value threshold of thickness difference corresponding to the environment, or the standard deviation of thickness difference exceeds the standard deviation threshold of thickness difference corresponding to the environment, it shows that the coating uniformity does not meet the requirement, and the coating uniformity correction coefficient needs to be calculated; if both evaluation indexes are within the corresponding threshold range, it shows that the coating uniformity meets the requirement, and the correction coefficient does not need to be calculated, the original dynamic control parameter is directly used.

[0062] The coating uniformity correction coefficient is divided into overall correction coefficient and local correction coefficient, both of which are in the range of 0.7-1.3, to avoid excessive adjustment leading to new thickness deviation, and to compensate for overall thickness deviation and local uniformity deviation respectively, if the average value of thickness difference is positive (overall thickness is thick), the overall correction coefficient = target thickness ÷ (target thickness + average value of thickness difference); if the average value of thickness difference is negative (overall thickness is thin), the overall correction coefficient = target thickness ÷ (target thickness - absolute value of average value of thickness difference); the coefficient is used to adjust the overall speed and powder feeding rate, so that the overall thickness approaches the target value; for the case that the standard deviation of thickness difference exceeds the threshold, the local correction coefficient = preset standard deviation threshold of thickness difference ÷ standard deviation of thickness difference; the coefficient is used to adjust the parameters of local area, to reduce the thickness difference of each area, and finally the coating uniformity correction coefficient = overall correction coefficient × local correction coefficient (if only overall correction or local correction is needed, the corresponding single coefficient is taken, and the result needs to be in the range of 0.7-1.3, otherwise 0.7 or 1.3 is taken as the correction coefficient); the correction coefficient greater than 1 indicates that the powder feeding rate needs to be increased or the spray gun speed needs to be reduced (to increase the thickness), and less than 1 indicates that the powder feeding rate needs to be reduced or the spray gun speed needs to be increased (to reduce the thickness).

[0063] Step 502, according to the coating uniformity correction coefficient, the proportional compensation adjustment is carried out on the gun moving speed and the powder feeding rate in the dynamic control parameter, the optimized dynamic control parameter is obtained, and specifically, the dynamic control parameter generated in step 302 is extracted, the gun moving speed and the corresponding powder feeding rate of each path point are contained, the original gun moving speed of each path point is determined, that is, the adjusted gun moving speed in step 302 and the original powder feeding rate, that is, the adjusted powder feeding rate in step 302; for each path point, the optimized gun moving speed = the original gun moving speed ÷ the coating uniformity correction coefficient; if the correction coefficient is greater than 1 (the thickness needs to be increased), the optimized speed is less than the original speed, the residence time of the gun at the point is prolonged to increase the attachment of zinc powder; if the correction coefficient is less than 1 (the thickness needs to be reduced), the optimized speed is greater than the original speed, the residence time of the gun is shortened to reduce the attachment of zinc powder; after adjustment, it is necessary to ensure that the optimized speed is still within the range of the maximum threshold (200-300 mm / s) and the minimum threshold (50-100 mm / s) of the gun moving speed preset in step 300, if it exceeds, the corresponding threshold value (lower than 50 mm / s, take 50 mm / s, higher than 300 mm / s, take 300 mm / s) is taken; according to the dynamic coupling relationship between the gun moving speed and the powder feeding rate established in step 301, that is, the powder feeding rate = unit area zinc powder projection amount × gun moving speed × gun effective spraying width, combined with the optimized gun moving speed, the optimized powder feeding rate is calculated, that is, the optimized powder feeding rate = unit area zinc powder projection amount × optimized gun moving speed × gun effective spraying width; it can also be directly calculated through proportional adjustment, that is, the optimized powder feeding rate = original powder feeding rate × coating uniformity correction coefficient (the result is consistent with the coupling relationship calculation); both calculation methods can ensure that the powder feeding rate matches the optimized speed and keeps the unit area zinc powder projection amount constant; the optimized gun moving speed and the corresponding optimized powder feeding rate of each path point are arranged into a parameter group, each parameter group contains the path point position, the optimized gun moving speed and the optimized powder feeding rate, and all parameter groups jointly constitute the optimized dynamic control parameter.

[0064] In this embodiment, the coating uniformity is quantified by the thickness difference average value and the thickness difference standard deviation, the subjectivity of the traditional experience-based judgment of uniformity is avoided, the uniformity evaluation is more accurate, the correction coefficient calculated based on the evaluation index can compensate the overall thickness deviation and the local uniformity deviation, the gun speed and the powder feeding rate are adjusted by proportion, the unit area zinc powder projection amount is kept constant, and the thickness deviation in the groove area, the hole area and the like which is prone to occur is corrected, the coating uniformity is further improved from the parameter level, and the local over-thick or over-thin defects caused by the fixed parameters are reduced.

[0065] In a preferred embodiment of the present application, the step 6 comprises:

[0066] At step 600, the spray gun is controlled to perform the spraying operation according to the adaptive spraying path and the optimized dynamic control parameters, and the coating thickness data of the three coating thickness measurement points on the thickness distribution reference plane are acquired in real time during the spraying process. Specifically, the adaptive spraying path generated at steps 200-202, i.e., the parallel path in the groove area, the surrounding path around the hole area, the constant row spacing path in the flat area, and the optimized dynamic control parameters generated at step 502 are input into the numerical control spraying system. The system controls the movement of the spray gun along the preset path according to the path instructions, and adjusts the movement speed of the spray gun in real time according to the optimized spray gun movement speed (50-300 mm / s) and the powder feeding rate parameters, to ensure that the spray gun moves along the path at the optimized speed with an error of not more than ±2 mm / s, and the powder feeding rate of the powder feeding device is ensured to deliver zinc powder at the optimized rate with an error of not more than ±0.1 g / s, to perform the flange zinc spraying operation. During the spraying operation, a real-time detection interval is set, the time setting value is 1-3 seconds, and the path length setting value is 5-10 mm, to ensure that the thickness change is captured in time, and the real-time coating thickness data of the three coating thickness measurement points (first, second, and third measurement points) on the thickness distribution reference plane are continuously collected by the laser thickness gauge (measurement accuracy ±1 μm). After each collection, the real-time data are transmitted to the numerical control system (transmission delay is not more than 0.5 seconds).

[0067] Step 601, according to the deviation of real-time coating thickness data and target thickness, dynamically adjust the speed of the spray gun and the powder feeding rate, when the real-time coating thickness data indicates that the coating uniformity exceeds the preset range, according to the deviation size to make local bias correction to the adaptive spraying path, including: for each collection of three measurement points, real-time thickness data, respectively, calculate the real-time thickness deviation of each point, real-time thickness deviation = real-time thickness value-target thickness, if the real-time thickness deviation of a measurement point is negative (the thickness is lower than the target value), reduce the speed of the spray gun on the path of the corresponding area of the measurement point, the reduction amplitude = the original optimized speed × the absolute value of the real-time thickness deviation ÷ the target thickness, wherein the original optimized speed is the speed of the spray gun after the optimization of the path point in step 502, the reduced speed is not less than the minimum threshold (50-100mm / s) of the speed of the spray gun preset in step 300, at the same time, increase the powder feeding rate of the corresponding area, the increase amplitude = the original optimized powder feeding rate × the absolute value of the real-time thickness deviation ÷ the target thickness, the increased powder feeding rate and the speed keep the coupling relationship, wherein the original optimized powder feeding rate is the powder feeding rate after the optimization of the path point in step 502, by prolonging the dwell time and increasing the zinc powder delivery, the thickness of the area is increased to the target value, if the real-time thickness deviation of a measurement point is positive (the thickness is higher than the target value), increase the speed of the spray gun on the path of the corresponding area of the measurement point, the increase amplitude = the original optimized speed × the real-time thickness deviation ÷ the target thickness, the increased speed does not exceed the maximum threshold (200-300mm / s) of the speed of the spray gun preset in step 300, at the same time, reduce the powder feeding rate of the corresponding area, the reduction amplitude = the original optimized powder feeding rate × the real-time thickness deviation ÷ the target thickness, the reduced powder feeding rate and the speed keep the coupling relationship, by shortening the dwell time and reducing the zinc powder delivery, the thickness of the area is reduced to the target value, after adjustment, it is necessary to ensure that the speed is still within the preset maximum (200-300mm / s) and minimum (50-100mm / s) threshold range, the powder feeding rate and the speed keep the dynamic coupling relationship established in step 301.

[0068] In the spraying process, the thickness difference standard deviation of the three measurement points is calculated in real time (calculation method step 500), and if the standard deviation exceeds the preset uniformity range, that is, exceeds the thickness difference standard deviation threshold of the corresponding environment in step 501, it indicates that the coating uniformity is out of standard, and local bias correction needs to be made to the adaptive spraying path. The area where the uniformity is out of standard is judged according to the thickness deviation, such as the first measurement point deviation being the largest, then the corresponding groove area is the bias area; the second measurement point deviation is the largest, then the corresponding hole area is the bias area; the third measurement point deviation is the largest, then the corresponding flat area is the bias area. The bias distance is calculated, bias distance = (the absolute value of the real-time thickness deviation of the measurement point in the area ÷ target thickness) × half of the effective spraying width of the spray gun, the bias distance value range is 0.5-5mm, to avoid excessive bias leading to path overlap or omission; the larger the deviation, the greater the bias distance, to ensure that the spraying coverage of the area is increased or decreased; the adaptive spraying path of the area out of standard is locally biased, such as the groove area path being biased to the side where the thickness is thinner, the hole area path being biased to the annular direction where the thickness is thinner, and the flat area path being biased to the direction where the thickness is thinner. After biasing, the spraying path coverage of the area is more sufficient. After each biasing, the thickness data is re-collected until the thickness difference standard deviation returns to the preset range, and the bias correction is stopped.

[0069] In this embodiment, the thickness data of the three key measurement points is obtained in real time, which can timely capture the thickness fluctuation in the spraying process, quickly correct the local thickness deviation by dynamically adjusting the speed and powder feeding rate, and avoid deviation accumulation; when the coating uniformity exceeds the preset range, the path coverage of the easy-to-exceed area can be targetedly optimized by local path bias correction, which can make up for the local coverage deficiency that cannot be solved by parameter adjustment alone, further ensure that the coating in the groove area, hole area and flat area can meet the uniformity requirement, and finally improve the overall coating quality of the flange plate and reduce the rework rate.

[0070] As shown in Figure 2 The embodiment of the present application also provides a path automatic planning and zinc spraying amount precise control system for numerical control zinc spraying of a flange plate, which comprises:

[0071] A region division module is configured to identify and divide key regions according to the three-dimensional structure of the flange plate, and the key regions include a groove area, a hole area and a flat area.

[0072] A path generation module is configured to generate adaptive spraying paths corresponding to the characteristics of each region according to the key regions, wherein the groove area is generated along the path of the groove, the hole area is generated as a bias path around the bolt hole, and the flat area is generated as an equidistant bias spiral path.

[0073] A parameter generation module is configured to establish a dynamic coupling relationship between the movement speed of the spray gun and the powder feeding rate according to the adaptive spraying path, and obtain dynamic control parameters for keeping the zinc powder projection amount per unit area constant.

[0074] a plane establishing module configured to set a coating thickness measurement point in the trench area, a hole peripheral area and a flat area respectively, and establish a thickness distribution reference plane according to the spatial positions of the three coating thickness measurement points;

[0075] an optimization control module configured to calculate a coating uniformity correction coefficient according to the thickness distribution reference plane, and compensate and adjust the dynamic control parameter to obtain an optimized dynamic control parameter;

[0076] a work execution module configured to execute the spraying work according to the self-adaptive spraying path and the optimized dynamic control parameter, and dynamically adjust the spraying gun path and the spraying amount parameter according to the real-time coating thickness data of the thickness distribution reference plane in the spraying process.

[0077] It should be noted that the system is corresponding to the above method, and all the implementation manners in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0078] Embodiments of the present application also provide a computing device, comprising a processor and a memory storing a computer program, wherein the computer program is executed by the processor to perform the method described above. All the implementation manners in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0079] Embodiments of the present application also provide a computer readable storage medium storing instructions, which, when executed on a computer, cause the computer to perform the method described above. All the implementation manners in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0080] The above is the preferred embodiment of the present application, and it should be noted that for those skilled in the art, without departing from the principles of the present application, a number of improvements and refinements can be made, and these improvements and refinements should also be considered as the protection scope of the present application.

Claims

1. A method for automatic path planning and precise control of zinc spraying quantity in CNC zinc spraying of flanges, characterized in that, The method includes: Step 1: Identify the sealing groove and stop area based on the geometric feature parameters in the three-dimensional structure of the flange, and divide the sealing groove and stop area into the groove area; divide the annular area around the bolt holes into the hole periphery area based on the hole array distribution characteristics in the three-dimensional structure of the flange; divide the continuous planar area on the flange surface other than the groove area and the hole periphery area into the flat area. Step 2: Extract the center line of the trench based on the three-dimensional contour data of the trench area, and generate an adaptive spraying path parallel to the direction of the trench based on the center line of the trench; determine the center coordinates of the bolt holes based on the bolt hole position parameters of the hole periphery area, and generate an adaptive spraying path around the bolt holes with a set offset distance based on the center coordinates of the bolt holes. The starting point of the path is determined based on the boundary contour features of the flat area, and an adaptive spraying path that maintains a constant row spacing is generated based on the starting point of the path. Step 3: Based on the adaptive spraying path, establish the dynamic coupling relationship between the spray gun moving speed and the powder feeding rate to obtain the dynamic control parameters used to maintain a constant amount of zinc powder projected per unit area. Step 4: Set a first coating thickness measurement point at the center of the trench area; set a second coating thickness measurement point at the center of the annular zone around the hole; set a third coating thickness measurement point at the center of the flat area. A thickness distribution reference plane is established based on the spatial coordinates of the first coating thickness measurement point, the second coating thickness measurement point, and the third coating thickness measurement point. Step 5: Calculate the coating uniformity correction coefficient based on the thickness distribution reference plane, and compensate and adjust the dynamic control parameters to obtain the optimized dynamic control parameters. Step 6: Based on the adaptive spraying path and optimized dynamic control parameters, control the spray gun to perform the spraying operation, and during the spraying process, acquire the coating thickness data of three coating thickness measurement points on the thickness distribution reference plane in real time; based on the deviation between the real-time coating thickness data and the target thickness, dynamically adjust the spray gun moving speed and powder feeding rate; when the real-time coating thickness data indicates that the coating uniformity exceeds the preset range, perform local offset correction on the adaptive spraying path according to the magnitude of the deviation.

2. The method for automatic path planning and precise control of zinc spraying quantity for CNC zinc spraying of flanges according to claim 1, characterized in that, Step 3 includes: Extract the curvature features of the adaptive spraying path, and calculate the baseline value of the spray gun movement speed based on the curvature features; Based on the reference value of the spray gun moving speed and the constant zinc powder projection amount per unit area, a dynamic coupling relationship between the spray gun moving speed and the powder feeding rate is established. Based on the dynamic coupling relationship and the changes in curvature characteristics, the reference value of the spray gun moving speed and the set value of the powder feeding rate are adjusted to obtain the adjustment results. Based on the adjustment results, dynamic control parameters are generated to maintain a constant zinc powder projection amount per unit area.

3. The method for automatic path planning and precise control of zinc spraying quantity for CNC zinc spraying of flanges according to claim 2, characterized in that, Step 5 includes: Based on the thickness distribution reference plane, the difference between the real-time coating thickness data and the target thickness at three coating thickness measurement points is analyzed to obtain the coating uniformity evaluation index. The coating uniformity correction coefficient is calculated by comparing the coating uniformity evaluation index with the preset uniformity threshold. Based on the coating uniformity correction coefficient, the spray gun moving speed and powder feeding rate in the dynamic control parameters are proportionally compensated and adjusted to obtain the optimized dynamic control parameters.

4. An automatic path planning and precise zinc spraying control system for CNC zinc spraying of flanges, wherein the system implements the method as described in any one of claims 1 to 3, characterized in that, include: The region division module is used to identify and divide key regions based on the three-dimensional structure of the flange. Key regions include the groove region, the hole periphery region, and the flat region. The path generation module is used to generate adaptive spraying paths corresponding to the characteristics of each key area; in the trench area, a path is generated along the direction of the trench. The periphery region generates an offset path around the bolt hole; the flat region generates a reciprocating path with constant row spacing. The parameter generation module is used to establish a dynamic coupling relationship between the spray gun moving speed and the powder feeding rate based on the adaptive spraying path, so as to obtain dynamic control parameters for maintaining a constant amount of zinc powder projected per unit area. The plane creation module is used to set a coating thickness measurement point in the trench area, the hole periphery area and the flat area respectively, and to create a thickness distribution reference plane based on the spatial position of the three coating thickness measurement points. The optimization control module is used to calculate the coating uniformity correction coefficient based on the thickness distribution reference plane, and to compensate and adjust the dynamic control parameters to obtain the optimized dynamic control parameters. The job execution module is used to execute the spraying operation based on the adaptive spraying path and optimized dynamic control parameters. During the spraying process, it dynamically adjusts the spray gun path and zinc spraying amount parameters based on the real-time coating thickness data of the thickness distribution reference plane.

5. A computing device, characterized in that, include: One or more processors; A storage device for storing one or more programs, which, when executed by one or more processors, cause the one or more processors to implement the method as described in any one of claims 1 to 3.

6. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a program that, when executed by a processor, implements the method as described in any one of claims 1 to 3.

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