A temperature automatic monitoring and fault early warning system for powder coating

Abstract

This application relates to an automated temperature monitoring and fault early warning system for powder coating, comprising a PLC control cabinet, a preheating furnace, a transfer robot, and a nylon powder-impregnated fluidized bed. The preheating furnace contains a circulating conveyor chain with multiple positioning slots evenly distributed along the chain for positioning workpieces. A position sensor switch is located at the outlet of the preheating furnace, and a temperature sensor and alarm are located at the outlet of the preheating furnace, in front of the conveying direction of the circulating conveyor chain. The position sensor switch, temperature sensor, alarm, and transfer robot are electrically connected to the PLC control cabinet. This invention belongs to the field of surface treatment technology. Through automated, full-inspection temperature monitoring, it completely avoids defective products from entering the next process due to human sampling oversight, fundamentally ensuring the uniformity and stability of coating quality and eliminating batch quality accidents.

Description

Technical Field

[0001] This application relates to the field of surface treatment technology, and in particular to an automated temperature monitoring and fault early warning system for powder coating. Background Technology

[0002] In powder coating processes, after the workpiece is heated in a preheating furnace, it needs to be transferred to a nylon powder-immersion fluidized bed for powder impregnation. During this process, the workpiece's exit temperature is a key parameter determining the coating quality. If the workpiece temperature is too low, the powder cannot fully melt and adhere, resulting in a thin coating and exposed substrate; if the workpiece temperature is too high, it may cause powder charring, affecting the coating's appearance and performance.

[0003] Currently, most production lines rely on manual, timed sampling or simple fixed-point temperature measurement to monitor workpiece temperature. Manual sampling is inherently delayed, cannot guarantee that every workpiece meets the temperature standard, and is inefficient. Simple fixed-point temperature measurement, on the other hand, suffers from inaccurate measurement points due to slight deviations in the workpiece's position on the conveyor chain, resulting in unreliable measurement results. If a workpiece with an unqualified temperature flows into the powder dipping process, it not only requires rework but may also contaminate the powder in the fluidized bed, leading to batch quality incidents and significant economic losses.

[0004] Therefore, there is an urgent need for an automated system that can automatically, in real time and accurately monitor the temperature of each workpiece exiting the furnace, and can provide timely warnings and sort out defective products. Summary of the Invention

[0005] Therefore, it is necessary to provide an automated temperature monitoring and fault early warning system for powder coating, and the specific technical solution is as follows.

[0006] An automated temperature monitoring and fault early warning system for powder coating includes a PLC control cabinet, a preheating furnace, a transfer robot, and a nylon impregnation fluidized bed. The preheating furnace contains a circulating conveyor chain with multiple positioning slots evenly distributed along it for workpiece positioning. A position sensor switch is located at the outlet of the preheating furnace. A temperature sensor and an alarm are located at the outlet of the preheating furnace, forward of the conveying direction of the circulating conveyor chain. The nylon impregnation fluidized bed is positioned on one side of the outlet of the preheating furnace. The transfer robot is positioned between the nylon impregnation fluidized bed and the preheating furnace. The position sensor switch, temperature sensor, alarm, and transfer robot are electrically connected to the PLC control cabinet and are uniformly coordinated and controlled by the PLC control cabinet.

[0007] Furthermore, the front end of the outlet of the preheating furnace is provided with a transverse slide rail, on which a slide table is provided. The temperature sensor is located on the slide table, and the transverse slide rail is provided with a screw drive mechanism to drive the slide table to slide; so that the temperature sensor can move laterally to adapt to the temperature measurement points of workpieces of different specifications.

[0008] Furthermore, the lead screw transmission mechanism includes a motor, a lead screw mounted on a transverse slide rail, and a nut mounted on a slide table, wherein the nut is adapted to the lead screw.

[0009] Furthermore, the lead screw is a reciprocating lead screw, and the motor is a servo motor. The reciprocating lead screw enables the slide to automatically reciprocate within a predetermined stroke, while the servo motor can precisely control the position and movement speed of the slide.

[0010] Furthermore, the slide is provided with a support, which includes a flat plate connected to the slide and an inclined plate bent upward at the rear end of the flat plate. The inclined plate has a through hole, and a flange structure for mounting the temperature sensor is provided on the back of the inclined plate around the through hole. The support provides a stable mounting base for the temperature sensor and the inclined plate design allows the sensor to be aligned with the workpiece at the optimal angle.

[0011] Furthermore, the inclined plate has protective plates bent towards the rear on both sides; the protective plates can effectively prevent dust and foreign objects from splashing onto the lens of the temperature sensor, prevent external structures from colliding with the temperature sensor, and ensure its measurement accuracy and service life.

[0012] Furthermore, the plate is provided with a longitudinal slide groove, and the longitudinal slide groove is provided with bolts connected to the slide table; by loosening the bolts, the position of the support and the temperature sensor on it in the longitudinal direction (i.e. the forward direction of the conveyor chain) can be adjusted to achieve fine-tuning of focus.

[0013] Furthermore, the alarm is an audible and visual alarm; the combination of sound and light can more effectively attract the attention of on-site operators.

[0014] Furthermore, when the position sensing switch detects that the workpiece has reached the outlet of the preheating furnace after heating is completed, it sends a signal to the controller of the PLC control cabinet.

[0015] Furthermore, after receiving the workpiece's position signal, the PLC control cabinet controller controls the temperature sensor to perform multiple temperature measurements on the workpiece and compares the workpiece's exit temperature t with the set lower limit Tmin and upper limit Tmax of the immersion powder temperature. If t is greater than Tmin and less than Tmax, the PLC control cabinet controller controls the transfer robot to transfer the workpiece to the nylon immersion powder fluidized bed for immersion powder processing. If t is less than Tmin or greater than Tmax, the PLC control cabinet controller sends an alarm signal to the alarm device and controls the transfer robot to remove the workpiece with the unqualified temperature to prevent it from flowing into the next process.

[0016] Furthermore, the lower limit of the immersion temperature Tmin is set to 220℃, the upper limit of the immersion temperature Tmax is set to 250℃, and the temperature sensor (8) measures more than 10 times per second.

[0017] Compared with existing technologies, the present invention has the following advantages: (1) The automatic temperature monitoring and fault early warning system for powder coating of the present invention, through automatic and full inspection temperature monitoring, completely avoids the flow of unqualified products into the next process due to human sampling omissions, and ensures the uniformity and stability of coating quality from the source, and eliminates batch quality accidents. (2) The automatic temperature monitoring and fault early warning system for powder coating of the present invention realizes full automation from detection and judgment to sorting without manual intervention, significantly reducing production stoppages caused by waiting for detection and handling of abnormalities, and improving the operating efficiency of the entire production line. (3) The automatic temperature monitoring and fault early warning system for powder coating of the present invention, with its movable temperature measuring mechanism and adjustable sensor support, enables the system to quickly adapt to the production needs of workpieces of different shapes and sizes, thereby enhancing the flexibility of the production line. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of the automated temperature monitoring and fault early warning system for powder coating of the present invention; Figure 2 This is a schematic diagram of the internal structure of the preheating furnace in this invention; Figure 3 yes Figure 2 Enlarged structural diagram at point A; Figure 4 This is an enlarged schematic diagram of the screw drive mechanism and support in this invention; Figure 5 This is an enlarged schematic diagram of the support structure in this invention.

[0020] Explanation of reference numerals in the attached figures: 1. PLC control cabinet; 2. Preheating furnace; 3. Transfer robot; 4. Nylon impregnation fluidized bed; 5. Circulating conveyor chain; 6. Positioning groove; 7. Position sensor switch; 8. Temperature sensor; 9. Alarm; 10. Transverse slide rail; 11. Slide table; 12. Motor; 13. Lead screw; 14. Nut; 15. Support; 16. Flat plate; 17. Inclined plate; 18. Protective plate; 19. Longitudinal chute; 20. Bolt. Detailed Implementation

[0021] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0022] The embodiments of the present invention will now be described.

[0023] Reference Figures 1-5 As shown, this embodiment provides an automated temperature monitoring and fault early warning system for powder coating, including a PLC control cabinet 1, a preheating furnace 2, a transfer robot 3, and a nylon impregnation fluidized bed 4. The preheating furnace 2 is equipped with a circulating conveyor chain 5, on which multiple positioning slots 6 for positioning workpieces are evenly distributed. A position sensing switch 7 is provided at the outlet of the preheating furnace 2. A temperature sensor 8 and an alarm 9 are provided at the outlet of the preheating furnace 2 in front of the conveying direction of the circulating conveyor chain 5. The nylon impregnation fluidized bed 4 is located on one side of the outlet of the preheating furnace 2. The transfer robot 3 is located between the nylon impregnation fluidized bed 4 and the preheating furnace 2. The position sensing switch 7, temperature sensor 8, alarm 9, and transfer robot 3 are electrically connected to the PLC control cabinet 1. In this invention, temperature measurement is triggered by position sensing, and the PLC compares the temperature data to control the robot to perform the transfer of qualified products or the sorting of unqualified products, thereby realizing fully automatic and closed-loop temperature monitoring and sorting, replacing manual labor, ensuring that the temperature of each workpiece is controlled, and eliminating batch quality accidents from the source.

[0024] Specifically, the front end of the outlet of the preheating furnace 2 is provided with a transverse slide rail 10, and a slide table 11 is provided on the transverse slide rail 10. The temperature sensor 8 is located on the slide table 11, and a screw drive mechanism is provided on the transverse slide rail 10 to drive the slide table 11 to slide. In this embodiment, the screw drive mechanism drives the slide table, which in turn drives the temperature sensor to scan laterally, so that the temperature measurement point can cover workpieces of different widths or positions, improving adaptability, measurement accuracy, and system flexibility, making it suitable for multi-variety production.

[0025] Specifically, the lead screw transmission mechanism includes a motor 12, a lead screw 13 mounted on a transverse slide rail 10, and a nut 14 mounted on a slide table 11, wherein the nut 14 is adapted to the lead screw 13. In this embodiment, the motor drives the lead screw to rotate, thereby driving the nut and the slide table to move linearly, providing a high-precision and high-efficiency linear transmission solution with stable structure, accurate transmission, and high reliability.

[0026] Specifically, the lead screw 13 is a reciprocating lead screw, and the motor 12 is a servo motor. In this embodiment, the servo motor precisely controls the reciprocating lead screw, enabling the slide to automatically reciprocate within a set stroke, thereby achieving automated scanning of the temperature sensor without manual intervention. This results in a higher degree of automation and allows for continuous scanning and temperature measurement of different parts of the workpiece or continuous workpieces.

[0027] Specifically, the slide table 11 is provided with a support 15, which includes a flat plate 16 connected to the slide table 11 and an inclined plate 17 bent upward at the rear end of the flat plate 16. The inclined plate 17 has a through hole, and a flange structure for mounting the temperature sensor 8 is provided around the through hole on the back side of the inclined plate 17. In this embodiment, the temperature sensor is a high-precision infrared temperature measuring device. The flange structure fixes the sensor, and the inclined plate aligns it with the workpiece at a specific angle, optimizing the sensor's installation posture, ensuring that it is aligned with the focal point, facilitating installation and maintenance, guaranteeing the accuracy of the temperature sensor measurement, ensuring stable installation, and allowing for adjustable angle.

[0028] Specifically, the inclined plate 17 has protective plates 18 bent towards the rear on both sides. In this embodiment, protective plates are added to the support to prevent collisions with external structures, protect the optical lens of the temperature sensor from contamination, extend the sensor's lifespan, maintain the accuracy of long-term measurements, and reduce maintenance.

[0029] Specifically, the plate 16 is provided with a longitudinal slide groove 19, and a bolt 20 connected to the slide table 11 is provided in the longitudinal slide groove 19. In this embodiment, a longitudinal position adjustment function of the support is added. Loosening the bolt allows the support to slide along the longitudinal slide groove, which can finely adjust the front and rear distance between the temperature sensor and the workpiece, enabling the system to focus precisely and adapt to different workpiece sizes or process changes, thus increasing flexibility.

[0030] Specifically, the alarm 9 is an audible and visual alarm that can emit sound and flashing signals simultaneously, ensuring that the alarm can be detected quickly in noisy industrial environments, thus improving the timeliness and effectiveness of early warning.

[0031] Specifically, when the position sensing switch 7 detects that the workpiece has reached the outlet of the front heating furnace 2 after heating is completed, it sends a signal to the controller of the PLC control cabinet 1. Specifically, after receiving the workpiece position signal, the controller of the PLC control cabinet 1 controls the temperature sensor 8 to perform multiple temperature measurements on the workpiece and compares the workpiece's exit temperature t with the set lower limit Tmin and upper limit Tmax of the immersion powder temperature. If t is greater than Tmin and less than Tmax, the controller of the PLC control cabinet 1 controls the transfer robot 3 to transfer the workpiece to the nylon immersion powder fluidized bed 4 for immersion powder processing. If t is less than Tmin or greater than Tmax, the controller of the PLC control cabinet 1 sends an alarm signal to the alarm 9 and controls the transfer robot 3 to remove the workpiece with the unqualified temperature to prevent it from flowing into the next process. The staff checks the reason for the workpiece's unqualified temperature based on the alarm signal from the alarm 9. The automated closed-loop control of "detection-judgment-execution" seamlessly connects temperature monitoring with execution actions, realizing truly intelligent production management and timely interception of unqualified products.

[0032] Specifically, the lower limit of the powder dipping temperature Tmin is set to 220℃, the upper limit of the powder dipping temperature Tmax is set to 250℃, and the temperature sensor 8 measures more than 10 times per second. In this embodiment, specific temperature thresholds and measurement frequencies are provided for the PLC's decision-making program, providing optimal process window assurance for nylon powder coating. High-frequency measurement ensures data reliability, and the specific temperature range guarantees the best coating effect for nylon powder.

[0033] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0034] The above embodiments only illustrate one or more implementation methods of this application, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. An automated temperature monitoring and fault early warning system for powder coating, comprising a PLC control cabinet (1), a preheating furnace (2), a transfer robot (3), and a nylon powder impregnation fluidized bed (4), wherein the preheating furnace (2) is provided with a circulating conveyor chain (5), and the circulating conveyor chain (5) is provided with a plurality of positioning grooves (6) for positioning workpieces evenly distributed thereon, characterized in that, The outlet of the preheating furnace (2) is equipped with a position sensing switch (7). The outlet of the preheating furnace (2) is located in front of the conveying direction of the circulating conveyor chain (5) and is equipped with a temperature sensor (8) and an alarm (9). The nylon impregnation fluidized bed (4) is located on one side of the outlet of the preheating furnace (2). The transfer robot (3) is located between the nylon impregnation fluidized bed (4) and the preheating furnace (2). The position sensing switch (7), temperature sensor (8), alarm (9) and transfer robot (3) are electrically connected to the PLC control cabinet (1). The front end of the outlet of the preheating furnace (2) is provided with a transverse slide rail (10), and a slide table (11) is provided on the transverse slide rail (10). The temperature sensor (8) is provided on the slide table (11), and a screw drive mechanism for driving the slide table (11) to slide is provided on the transverse slide rail (10). The slide (11) is provided with a support (15), the support (15) includes a flat plate (16) connected to the slide (11) and an inclined plate (17) bent upward at the rear end of the flat plate (16). The inclined plate (17) is provided with a through hole, and a flange structure for installing the temperature sensor (8) is provided around the through hole on the back side of the inclined plate (17). When the position sensing switch (7) detects that the workpiece has reached the outlet of the front heating furnace (2) after heating is completed, it sends a signal to the controller of the PLC control cabinet (1); After receiving the position signal of the workpiece, the controller of the PLC control cabinet (1) controls the temperature sensor (8) to perform multiple temperature measurements on the workpiece and compares the workpiece's exit temperature t with the set lower limit Tmin and upper limit Tmax of the immersion powder temperature. If t is greater than Tmin and less than Tmax, the controller of the PLC control cabinet (1) controls the transfer robot (3) to transfer the workpiece to the nylon immersion powder fluidized bed (4) for immersion powder processing. If t is less than Tmin or greater than Tmax, the controller of the PLC control cabinet (1) sends an alarm signal to the alarm (9) and controls the transfer robot (3) to remove the workpiece with unqualified temperature to prevent it from flowing into the next process.

2. The temperature automatic monitoring and failure warning system for powder coating according to claim 1, characterized in that, The lead screw transmission mechanism includes a motor (12), a lead screw (13) on a transverse slide rail (10), and a nut (14) on a slide table (11), wherein the nut (14) is adapted to the lead screw (13).

3. The temperature automatic monitoring and failure warning system for powder coating according to claim 2, characterized in that, The lead screw (13) is a reciprocating lead screw, and the motor (12) is a servo motor.

4. The temperature automatic monitoring and failure warning system for powder coating according to claim 1, characterized in that, The inclined plate (17) is provided with protective plates (18) that bend towards the rear on both sides.

5. The temperature automatic monitoring and failure warning system for powder coating according to claim 4, wherein, The plate (16) is provided with a longitudinal groove (19), and the longitudinal groove (19) is provided with a bolt (20) connected to the slide (11).

6. The temperature automatic monitoring and failure warning system for powder coating according to claim 1, wherein, The alarm (9) is an audible and visual alarm.

7. The automated temperature monitoring and fault early warning system for powder coating according to claim 1, characterized in that, The lower limit of the immersion temperature Tmin is set to 220℃, the upper limit of the immersion temperature Tmax is set to 250℃, and the temperature sensor (8) measures more than 10 times per second.

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