Automatic placing and conveying control method for steel bar thermal spraying production line

Abstract

This invention discloses an automatic placement and conveying control method for a rebar thermal spraying production line, relating to the field of production control technology. It addresses the problem of low production efficiency by accessing a dust database to retrieve flue flow data for the spraying area. The spraying area is divided into sections, and dust sensors are marked in each section. When the rebar to be sprayed enters the spraying area, dust concentration data from each marked dust sensor is collected, and the dust distribution in each section is analyzed. Combined with spray gun flow rate data, the spraying quality and efficiency characteristics of each section are evaluated. This determines whether the conveying spacing of the rebar needs adjustment. The spray gun duty cycle coefficient and rebar placement vibration data before spacing adjustment are collected and calculated, and the rebar conveying characteristics are fused to obtain the rebar conveying characteristics. The conveying spacing is then corrected based on this, and the adjustment effect is further verified based on the peak dust concentration, ensuring environmental stability and consistent spraying quality in the spraying area.

Description

Technical Field

[0001] This invention relates to the field of production control technology, and more specifically, to an automatic placement and conveying control method for a steel bar thermal spraying production line. Background Technology

[0002] As a commonly used anti-corrosion treatment process in construction engineering, the quality of steel bar thermal spraying directly affects the durability and service life of the structure. In traditional steel bar thermal spraying production lines, the spraying operation usually relies on manual labor or simple automated equipment to complete the steel bar conveying and spraying control.

[0003] The existing technology has the following shortcomings:

[0004] Currently, existing technologies lack real-time monitoring and segmented analysis of dust concentration in the spraying area during the conveying and spraying of reinforcing bars. This easily leads to uneven spraying thickness, with some areas being too thick or too thin. Furthermore, there is a lack of a dynamic conveying spacing adjustment mechanism based on spray gun flow rate, spraying duty cycle, and data on the shaking of the reinforcing bars. Consequently, it is difficult to guarantee the quality and efficiency of spraying, resulting in low production efficiency. Environmental control and spraying quality cannot be optimized in a closed loop. Therefore, an automatic placement and conveying control method for a thermal spraying production line for reinforcing bars is proposed.

[0005] The information disclosed in the background section is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0006] To overcome the aforementioned deficiencies of the prior art, embodiments of the present invention provide an automatic placement and conveying control method for a steel bar thermal spraying production line. This method utilizes a closed-loop control algorithm based on segmented dust analysis using dust sensor data, monitoring of spray gun flow and duty cycle, detection of steel bar placement vibration, and dynamic adjustment of conveying spacing to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: an automatic placement and conveying control method for a steel bar thermal spraying production line, comprising the following steps:

[0008] Step S1: After accessing the dust database and retrieving the flue flow direction data, the spraying operation area is divided into sections. The dust sensors in each section are retrieved and marked. When the steel reinforcement to be sprayed enters the spraying operation area, the dust concentration data of each marked dust sensor is collected.

[0009] Step S2: Analyze the dust distribution status of the divided sections based on dust concentration data, detect the spraying flow rate data of the spray gun, evaluate the spraying quality and efficiency characteristics of the divided sections in combination with the dust distribution status, and determine whether to adjust the conveying spacing of the steel bars to be sprayed based on the spraying quality and efficiency characteristics.

[0010] Step S3: Before adjusting the conveying spacing, set a statistical time, collect the cumulative time of the spray gun spraying work within the statistical time and calculate the duty cycle coefficient, and detect the placement vibration data of the steel bars to be sprayed.

[0011] Step S4: Evaluate the rebar conveying characteristics by combining the duty cycle coefficient and placement jitter data, and correct the conveying spacing based on the rebar conveying characteristics. After correction, collect the peak dust concentration of the marked dust sensor to determine whether to make a secondary adjustment to the conveying spacing.

[0012] In a preferred embodiment, in step S1, the smoke and dust database is accessed to retrieve the flue flow direction data corresponding to the spraying operation area;

[0013] The dust database is a structured data collection used to store dust flow parameters, flow field change records, and historical concentration data at various monitoring locations within the spraying operation area;

[0014] The flue gas flow direction data includes the mainstream angle of the flue gas and the average flow velocity of the flue gas. The mainstream angle of the flue gas is the average value of the instantaneous flow direction angles of all flow velocity monitoring positions monitored by the flow direction monitoring unit.

[0015] The average velocity of the smoke and dust is the average value of the instantaneous velocity measured by the flow direction monitoring unit within a fixed monitoring period;

[0016] The flow direction monitoring unit has several fixed installation points along the main flow direction in the spraying operation area, and each installation point is a flow velocity monitoring position.

[0017] In a preferred embodiment, in step S1, when dividing the spraying operation area into sections based on flue flow direction data, the main axis direction of flue flow within the spraying operation area is determined by the main flue flow direction angle.

[0018] All velocity monitoring positions are arranged sequentially along the main axis of the spraying operation area, and the difference in average dust velocity between the velocity monitoring position and the adjacent previous velocity monitoring position is calculated point by point.

[0019] When the average velocity difference of the smoke and dust reaches or exceeds the preset velocity change threshold, the spatial location corresponding to the velocity monitoring location is defined as the segment boundary, forming the upstream segment, the midstream segment and the downstream segment in sequence.

[0020] The dust sensors deployed in each section are invoked and section marking is executed. The dust sensors are online dust concentration detection devices pre-installed in the spraying operation area.

[0021] Once the steel bars to be sprayed enter the spraying operation area, the marked dust sensor in the corresponding section is activated to collect the mass concentration of suspended particulate matter in a unit volume of air to obtain dust concentration data.

[0022] In a preferred embodiment, in step S2, the weighted average of the dust concentration data measured by the dust sensors in each segment of the spraying operation area is calculated to obtain the dust distribution status.

[0023] The spray flow rate data is obtained by measuring the volume output of the spray material per unit time in real time using a spray flow sensor installed in the spray gun feed channel.

[0024] The spray flow rate data and dust distribution status were standardized to obtain the spray flow rate factor and dust distribution factor.

[0025] By comprehensively calculating the spraying flow rate factor and dust distribution factor, the spraying quality and efficiency characteristics of the divided sections are obtained: ;

[0026] in, For the quality and efficiency characteristics of spraying, For the spraying flow factor, This represents the distribution factor of smoke and dust.

[0027] In a preferred embodiment, in step S2, the spraying quality characteristics are compared with a preset spraying quality threshold:

[0028] When the spraying quality and efficiency characteristics are greater than or equal to the preset spraying quality and efficiency threshold, it is determined that there is no need to adjust the conveying spacing of the steel bars to be sprayed.

[0029] When the spraying quality characteristics are less than the preset spraying quality threshold, it is determined that the conveying spacing of the steel bars to be sprayed needs to be adjusted to improve the spraying environment.

[0030] In a preferred embodiment, in step S3, before adjusting the conveying distance, a preset statistical time is set, and the cumulative time for the spray gun to perform spraying work is obtained through the spray gun operation database within the preset statistical time.

[0031] The ratio of the cumulative duration to the preset statistical time is used as the duty cycle coefficient;

[0032] The coordinate points of the continuous position of the steel bar to be sprayed after it is placed are collected by a laser displacement sensor.

[0033] The difference between the coordinates of each position and the preset placement position is calculated using the Euclidean distance algorithm, and this difference is used as the placement position offset value.

[0034] In a preferred embodiment, in step S3, the maximum value of the placement position offset is taken as the shaking offset amplitude of the steel bar to be sprayed.

[0035] Within a preset statistical time period, the fluctuation of the placement position is calculated based on the shaking offset amplitude of each steel bar to be sprayed;

[0036] The fluctuation in the placement position is used as the placement vibration data for the steel bars to be sprayed.

[0037] In a preferred embodiment, in step S4, the duty cycle coefficient and the placement jitter data are standardized to obtain the duty cycle factor and the placement jitter factor.

[0038] The characteristics of rebar delivery are calculated based on duty cycle factor and placement jitter factor;

[0039] The product of the steel bar conveying characteristics and the preset balance coefficient is used as the conveying spacing adjustment index;

[0040] The adjusted conveying spacing is the product of the conveying spacing adjustment index and the current conveying spacing of the steel bars to be sprayed.

[0041] In a preferred embodiment, in step S4, after correcting the conveying distance, a preset sampling period is set, and the dust concentration data of the marked dust sensor is acquired within the preset sampling period. The maximum value of the dust concentration data is taken as the peak dust concentration.

[0042] Access the historical database to retrieve the concentration peak reference, which refers to the reference value of the peak concentration of smoke and dust in the spraying operation area obtained based on historical production data statistics;

[0043] If the peak concentration of smoke and dust is greater than the peak concentration benchmark, then it is determined that the conveying spacing should be adjusted a second time.

[0044] Conversely, if the conditions are not met, it is determined that no further adjustment of the conveying spacing will be made.

[0045] In a preferred embodiment, in step S4, when the conveying spacing is adjusted a second time, the difference between the peak dust concentration and the peak concentration reference is used as the concentration offset.

[0046] The gain adjustment index is calculated based on the concentration offset, and the product of the current delivery spacing and the gain adjustment index is used as the delivery spacing after secondary adjustment.

[0047] The technical effects and advantages of this invention are as follows:

[0048] This invention retrieves flue gas flow data from a dust database to divide the spraying area into sections and marks the dust sensors deployed in each section. When the rebar to be sprayed enters the spraying area, dust concentration data from each marked dust sensor is collected and the dust distribution in each section is analyzed. Combined with spray gun flow data, the spraying quality and efficiency characteristics of each section are evaluated to determine whether the conveying spacing of the rebar to be sprayed needs adjustment. The spray gun duty cycle coefficient and rebar placement vibration data before the conveying spacing adjustment are collected and calculated, and the rebar conveying characteristics are fused to obtain the rebar conveying characteristics. The conveying spacing is then corrected accordingly. The adjustment effect is further verified based on the peak dust concentration, and a secondary spacing adjustment is performed if necessary, thereby ensuring environmental stability and consistent spraying quality in the spraying area. Attached Figure Description

[0049] Figure 1 This is a flowchart illustrating the implementation of an automatic placement and conveying control method for a steel bar thermal spraying production line according to the present invention.

[0050] Figure 2 This is a schematic diagram illustrating the steps of an automatic placement and conveying control method for a steel bar thermal spraying production line according to the present invention. Detailed Implementation

[0051] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0052] This invention retrieves flue flow data from a dust database to divide the spraying area into sections and marks the dust sensors installed in each section. When the rebar to be sprayed enters the spraying area, the dust concentration data of each marked dust sensor is collected and the dust distribution in each section is analyzed. Combined with the spray gun flow rate data, the spraying quality and efficiency characteristics of each section are evaluated to determine whether the conveying spacing of the rebar to be sprayed needs to be adjusted. The spray gun duty cycle coefficient and rebar placement vibration data before the conveying spacing adjustment are collected and calculated, and the rebar conveying characteristics are fused to obtain the rebar conveying characteristics. The conveying spacing is then corrected accordingly. The adjustment effect is further verified based on the peak dust concentration.

[0053] Example 1, as Figures 1 to 2 As shown, an automatic placement and conveying control method for a steel bar thermal spraying production line includes the following steps:

[0054] Step S1: After accessing the dust database and retrieving the flue flow direction data, the spraying operation area is divided into sections. The dust sensors in each section are retrieved and marked. When the steel reinforcement to be sprayed enters the spraying operation area, the dust concentration data of each marked dust sensor is collected.

[0055] Step S2: Analyze the dust distribution status of the divided sections based on dust concentration data, detect the spraying flow rate data of the spray gun, evaluate the spraying quality and efficiency characteristics of the divided sections in combination with the dust distribution status, and determine whether to adjust the conveying spacing of the steel bars to be sprayed based on the spraying quality and efficiency characteristics.

[0056] Step S3: Before adjusting the conveying spacing, set a statistical time, collect the cumulative time of the spray gun spraying work within the statistical time and calculate the duty cycle coefficient, and detect the placement vibration data of the steel bars to be sprayed.

[0057] Step S4: Evaluate the rebar conveying characteristics by combining the duty cycle coefficient and placement jitter data, and correct the conveying spacing based on the rebar conveying characteristics. After correction, collect the peak dust concentration of the marked dust sensor to determine whether to make a secondary adjustment to the conveying spacing.

[0058] The specific implementation is as follows:

[0059] In step S1, during the production process of thermal spraying of steel bars, the spray gun releases a large amount of smoke and dust during continuous spraying. The smoke and dust will continue to spread and accumulate along the spraying area with the airflow. When the steel bars are transported too densely into the spraying area, the rate of smoke and dust generation during the spraying process increases significantly, resulting in a rapid increase in the smoke and dust concentration in the spraying area, which affects the spraying quality. The spraying area is divided into sections and the changes in smoke and dust in different sections are monitored to determine whether the conveying spacing of the steel bars should be adjusted.

[0060] Access the dust database to retrieve the flue flow direction data corresponding to the spraying operation area. The dust database is a structured data set used to store dust flow parameters, flow field change records and historical concentration data at each monitoring location in the spraying operation area. It includes flue flow direction data collected and recorded by the flow direction monitoring unit. The flue flow direction data are parameters that characterize the flow trend of dust in the spraying operation area, including the mainstream angle of dust and the average flow velocity of dust.

[0061] The mainstream flow angle of the smoke and dust is a directional parameter calculated by the flow direction monitoring unit based on the monitored instantaneous flow direction vector. It is used to characterize the dominant flow direction of the smoke and dust in the overall flow area of ​​the spraying operation. Specifically, it is obtained by calculating the average value of the instantaneous flow direction angle at all flow velocity monitoring locations.

[0062] The average flow velocity of the smoke and dust is the average value of the instantaneous flow velocity measured by the flow direction monitoring unit within a fixed monitoring period, which is used to reflect the overall flow intensity of the smoke and dust in the spraying operation area.

[0063] It should be noted that the spraying operation area is a fixed spatial section where the spray gun performs thermal spraying on the steel bars to be sprayed, and its boundary is defined by the position of the spray gun and the steel bar conveying path; the flow direction monitoring unit is a flow field monitoring device installed in the spraying operation area and its exhaust channel, used to measure the flow direction and flow velocity of the air-dust mixture in real time; the flow direction monitoring unit has several fixed installation points along the main flow direction in the spraying operation area, and each installation point is a flow velocity monitoring position. Each flow velocity monitoring position corresponds to a single monitoring coordinate and outputs an independent instantaneous flow direction angle and instantaneous flow velocity, which are the basic sampling points used to determine the characteristics of the change in dust flow velocity between sections and to determine the boundaries of the sections.

[0064] When dividing the spraying operation area into sections based on flue gas flow direction data, the spray gun placement position is used as a reference point, and the main axis direction of flue gas flow within the spraying operation area is determined by the main flow direction angle. The average flue gas velocity reflects the change in flow gradient along the main axis direction, dividing the spraying operation area into multiple sections along the main axis direction to distinguish the differences in flue gas concentration and flow at upstream, midstream, and downstream locations. Specifically, all velocity monitoring positions are sequentially arranged along the determined main axis direction of the spraying operation area, and the average flue gas velocity at each velocity monitoring position is read. The difference in average flue gas velocity between the velocity monitoring position and its adjacent previous velocity monitoring position is calculated point by point. When the difference in average flue gas velocity reaches or exceeds a preset velocity change threshold, it indicates that the flow state of flue gas at that position has changed significantly relative to the previous area. Therefore, the spatial position corresponding to the velocity monitoring position is defined as the section boundary, thus forming the upstream section, midstream section, and downstream section in sequence.

[0065] It should be noted that the velocity change threshold is a judgment parameter used to determine whether the difference in average dust velocity between adjacent velocity monitoring locations is sufficient to constitute a section boundary. It is set based on historical operation data to statistically analyze the range of average dust velocity change at each velocity monitoring location under different exhaust loads, different spraying cycles, and different steel bar conveying speeds. The velocity difference between adjacent velocity monitoring locations is calculated to form a set of differences, and the sum of the mean and standard deviation of the set of differences is used as the velocity change threshold.

[0066] After the section division is completed, the dust sensors deployed in each section are called up and the section marking is executed. The dust sensors are online dust concentration detection devices pre-installed in the spraying operation area, and each dust sensor corresponds to a single fixed sampling position.

[0067] Once the steel bars to be sprayed enter the spraying operation area, the marked dust sensors in the corresponding sections are immediately activated to collect dust concentration data in real time. The dust concentration data is the mass concentration of suspended particulate matter per unit volume of air. The dust sensor uses the principle of light scattering to calculate the dust concentration data by measuring the response of airborne particulate matter to a light beam. The internal light source of the dust sensor emits a light beam. When the air and dust mixture passes through the measuring chamber of the dust sensor, the suspended particulate matter scatters the light. There is a corresponding relationship between the intensity of the scattered light and the concentration of particulate matter. The measured intensity of the scattered light is multiplied by a preset calibration coefficient using a calibration formula to convert it into dust concentration data.

[0068] In step S2, based on the dust concentration data from the marked dust sensors, the dust distribution status of each segment of the spraying area is calculated. The dust distribution status is the weighted average of the dust concentration data measured by the dust sensors in the corresponding segment, and the calculation formula is as follows:

[0069] ;

[0070] in, The distribution state of smoke and dust. For the smoke concentration data of the i-th smoke sensor, The distance weight of the dust sensor is determined based on the spatial distance between the dust sensor and the spray gun. The closer the dust sensor is to the spray gun, the higher the distance weight. The specific value is calculated by inversely proportional to the distance based on the actual placement position.

[0071] The distribution of smoke and dust reflects the degree of smoke and dust accumulation in the spraying operation area. The higher the value, the higher the smoke and dust concentration in that area, which increases the burden on the exhaust system and may affect the spraying quality. The lower the value, the more uniform the smoke and dust diffusion, the better the environmental conditions, and the more conducive it is to the stable operation of the spraying.

[0072] When detecting the spraying flow rate data of the spray gun, the spraying flow rate sensor installed in the spray gun feeding channel measures the volume output of the spraying material per unit time in real time to obtain the spraying flow rate data. The spraying flow rate sensor is a flow meter based on the principle of differential pressure detection or electromagnetic induction. Its output spraying flow rate data reflects the spraying intensity of the spray gun under the current spraying conditions.

[0073] Spray flow rate data reflects the intensity of the sprayed material output by the spray gun per unit time. The higher the value, the higher the spraying intensity, which may be accompanied by more smoke and dust; the lower the value, the lower the spraying intensity, and the less smoke and dust is generated.

[0074] It should be noted that the spraying flow sensor is a flow measurement device based on differential pressure detection or electromagnetic induction. It is installed in the feed channel of the spray gun to monitor the volume output of the spraying material per unit time in real time. Its output data directly reflects the working intensity of the spray gun.

[0075] To eliminate the differences in dimensions and orders of magnitude between the spraying flow rate data and the dust distribution status, the spraying flow rate data and the dust distribution status are standardized to obtain the spraying flow rate factor and the dust distribution factor.

[0076] The spraying flow rate factor and dust distribution factor are comprehensively calculated to obtain the spraying quality and efficiency characteristics of the divided sections. The specific calculation formula is as follows:

[0077] ;

[0078] in, For the quality and efficiency characteristics of spraying, For the spraying flow factor, This represents the distribution factor of smoke and dust.

[0079] The spraying quality and efficiency characteristics are used to comprehensively evaluate the efficiency and environmental impact of the current spraying operation. A higher value indicates that a higher spraying efficiency has been achieved with a lower dust load, while a lower value indicates that the spraying environment is not suitable for the current work intensity.

[0080] It should be noted that standardization refers to the process of mapping raw data of different physical quantities or different dimensions to a uniform dimension, uniform numerical range or uniform statistical distribution through a specific mathematical transformation. Standardization methods include, but are not limited to, standard linear transformation based on interval scaling, Z-Score standardization based on statistics or normalization method based on nonlinear mapping function. The application methods of standardization will not be elaborated here.

[0081] The spraying quality characteristics are compared with the preset spraying quality thresholds:

[0082] When the spraying quality and efficiency characteristics are greater than or equal to the preset spraying quality and efficiency threshold, it indicates that the current spraying operation still maintains high efficiency under a low dust load, and it is determined that there is no need to adjust the conveying spacing of the steel bars to be sprayed.

[0083] When the spraying quality and efficiency characteristics are less than the preset spraying quality and efficiency threshold, it indicates that the spraying operation may have a decrease in quality and efficiency due to the accumulation of smoke and dust or improper spraying intensity. It is determined that the conveying spacing of the steel bars to be sprayed needs to be adjusted to improve the spraying environment.

[0084] It should be noted that the spraying quality and efficiency threshold is a criterion used to determine whether a spraying operation section meets the expected spraying quality and efficiency. Its value is determined by historical spraying operation data and standard spraying operation requirements. Specifically, the dust concentration and spray gun flow rate of each section are collected over a long period of time, the corresponding data distribution of spraying quality and efficiency characteristics is calculated, and the sum of its mean and standard deviation is used as the spraying quality and efficiency threshold.

[0085] In step S3, before adjusting the conveying distance, a preset statistical time is set. During the preset statistical time, the cumulative time of the spray gun's spraying operation is obtained through the spray gun operation database. The cumulative time refers to the total time of all continuous periods when the spray gun is in the spraying operation state within the preset statistical time. The longer the cumulative time, the more dense the spraying rhythm of the spray gun within the preset statistical time, and the more dust is generated during the spraying process.

[0086] The ratio of the cumulative duration to the preset statistical time is used as the duty cycle coefficient;

[0087] The larger the duty cycle coefficient, the higher the proportion of the spray gun being in the spraying operation state within the preset statistical time, the more intensive the spraying activity, the faster the instantaneous dust generation rate in the spraying area, and the stronger the constraint on the conveying rhythm of the subsequent steel bars to be sprayed. Increasing the conveying distance can prevent the steel bars from entering too densely and causing a decrease in spraying quality.

[0088] The laser displacement sensor collects the continuous position coordinates of the steel bar to be sprayed after it is placed. The Euclidean distance algorithm is used to calculate the difference between each position coordinate and the preset placement position coordinate. The result is used as the placement position offset value. The maximum value of the placement position offset value is used as the shaking offset amplitude of the steel bar to be sprayed.

[0089] Within a preset statistical time period, the fluctuation in placement position is calculated based on the shaking offset amplitude of each steel bar to be sprayed: ,in, Let be the vibration offset amplitude of the i-th steel bar to be sprayed. This is the index value, ranging from 1 to n. The number of steel bars to be automatically placed within a preset time. This refers to the fluctuation in placement position;

[0090] The fluctuation in the placement position is used as the placement vibration data for the steel bars to be sprayed;

[0091] The greater the shaking data, the worse the stability of the steel bars to be sprayed after automatic placement. The steel bars to be sprayed are prone to rolling or swaying. Increasing the conveying distance ensures the spraying quality.

[0092] It should be noted that the preset statistical time can be set according to the spraying cycle or the allowable dust concentration range; the spray gun operation database is a database used to store the operating status of the spray gun equipment, including spray gun start and stop marks and spraying duration records; the laser displacement sensor is a distance measuring sensor that uses a laser beam to illuminate the surface of the target to be measured, and obtains the change in target position by receiving the reflected light and calculating the optical path difference; the Euclidean distance algorithm is a spatial distance calculation method based on a rectangular coordinate system, which calculates the straight-line distance between coordinate points; the preset drop position coordinates can be set according to the geometric center position of the conveyor line, the specifications and dimensions of the reinforcing bars, and the automatic placement drop trajectory.

[0093] By setting a statistical time before adjusting the conveyor spacing, and obtaining the cumulative spraying time of the spray gun and the shaking data of the steel bars to be sprayed within that statistical time, the working load of the spraying area and the stability of the steel bar placement can be evaluated simultaneously. This avoids uneven spraying or dust accumulation caused by excessively dense entry of steel bars, thereby improving the spraying quality and operational stability of the production line.

[0094] In step S4, the duty cycle coefficient and the placement jitter data are standardized to obtain the duty cycle factor and the placement jitter factor.

[0095] Calculation of rebar delivery characteristics based on duty cycle factor and placement jitter factor: ,in, Features of steel bar conveying Duty cycle factor To place the jitter factor, It is a natural constant. and The preset slope coefficient;

[0096] The larger the steel bar conveying characteristics, the higher the spray gun duty cycle and the more obvious the shaking of the steel bars to be sprayed. The conveying distance should be increased to reduce the density of the steel bars to be sprayed entering the spraying operation area.

[0097] The product of the steel bar conveying characteristics and the preset balance coefficient is used as the conveying spacing adjustment index;

[0098] The adjusted conveying spacing is the product of the conveying spacing adjustment index and the current conveying spacing of the steel bars to be sprayed.

[0099] After correcting the conveying distance, a preset sampling period is set, and the dust concentration data of the marked dust sensor is obtained within the preset sampling period. The maximum value of the dust concentration data is taken as the peak dust concentration.

[0100] Access the historical database to retrieve the concentration peak reference, which refers to the reference value of the peak concentration of smoke and dust in the spraying operation area obtained based on historical production data statistics;

[0101] Compare the peak concentration baseline with the peak dust concentration to determine whether a secondary adjustment to the conveyor spacing is necessary.

[0102] If the peak concentration of smoke and dust is greater than the peak concentration benchmark, then it is determined that the conveying spacing should be adjusted a second time.

[0103] Conversely, if the condition is not met, it is determined that no further adjustment of the conveying spacing will be made.

[0104] When making a secondary adjustment to the conveying distance, the gain adjustment index is set based on the current conveying distance, and the correction is made according to the deviation between the peak dust concentration and the peak concentration reference. The difference between the peak dust concentration and the peak concentration reference is used as the concentration offset.

[0105] Calculate the gain adjustment index based on the concentration offset: ,in, This is the concentration offset. As a benchmark for peak concentration, This is the preset gain scaling factor. The gain adjustment index;

[0106] The product of the current conveying spacing and the gain adjustment index is used as the conveying spacing after secondary adjustment. The conveying cycle of the steel bars to be sprayed is updated based on the conveying spacing after secondary adjustment to ensure the stability of the spraying quality.

[0107] It should be noted that the preset slope coefficient can be set according to the sensitivity of the spraying equipment to changes in duty cycle and placement vibration; the preset balance coefficient can be set according to the load margin of the exhaust system in the spraying operation area and the production requirements of the rebar conveying cycle; the preset sampling period can be set according to the rate of change of dust concentration in the spraying area and the sampling capability of the dust sensor; the historical database is used to store multi-cycle dust concentration data generated during the spraying production process, including the peak concentration benchmark obtained by statistical analysis of historical production data; the preset gain scaling coefficient can be set according to the sensitivity of the rebar conveying cycle in the spraying operation area to the spraying quality and the impact of gain correction in historical adjustment records on dust stability.

[0108] This step integrates the duty cycle coefficient and placement jitter data to form the rebar conveying characteristics, thereby identifying the risks of increased load in the spraying area or unstable rebar placement in advance. By increasing the conveying spacing, problems such as spraying obstruction and uneven spraying caused by dense rebar entry are reduced. Combined with a secondary adjustment mechanism, the conveying spacing can be further adjusted by using changes in dust concentration for closed-loop correction, so that the final spacing is more in line with the current spraying conditions and improves the stability of spraying quality.

[0109] Finally, it should be noted that in this paper, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0110] Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0111] In this document, the singular forms “a,” “an,” and “the” may also include the plural forms unless the context clearly indicates otherwise. It should also be understood that terms such as “comprising / including” or “having” specify the presence of the stated features, integrals, steps, operations, components, parts, or combinations thereof, but do not preclude the possibility of the presence or addition of one or more other features, integrals, steps, operations, components, parts, or combinations thereof. Meanwhile, the term “and / or” as used in this specification includes any and all combinations of the associated listed items.

[0112] The various embodiments in this specification are described in a progressive manner. Each embodiment focuses on the differences from other embodiments. The various embodiments can be combined as needed, and the same or similar parts can be referred to each other.

[0113] The above description of the disclosed embodiments will enable those skilled in the art to make or use various modifications to these embodiments. It will be readily apparent to those skilled in the art that the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An automatic placement and conveying control method for a steel bar thermal spraying production line, characterized in that: Includes the following steps: Step S1: After accessing the dust database and retrieving the flue flow direction data, the spraying operation area is divided into sections. The dust sensors in each section are retrieved and marked. When the steel reinforcement to be sprayed enters the spraying operation area, the dust concentration data of each marked dust sensor is collected. Step S2: Analyze the dust distribution status of the divided sections based on dust concentration data, detect the spraying flow rate data of the spray gun, evaluate the spraying quality and efficiency characteristics of the divided sections in combination with the dust distribution status, and determine whether to adjust the conveying spacing of the steel bars to be sprayed based on the spraying quality and efficiency characteristics. In step S2, the weighted average of the dust concentration data measured by the dust sensors in each segment of the spraying operation area is calculated to obtain the dust distribution status. The spray flow rate data is obtained by measuring the volume output of the spray material per unit time in real time using a spray flow sensor installed in the spray gun feed channel. The spray flow rate data and dust distribution status were standardized to obtain the spray flow rate factor and dust distribution factor. By comprehensively calculating the spraying flow rate factor and dust distribution factor, the spraying quality and efficiency characteristics of the divided sections are obtained: ; in, For the quality and efficiency characteristics of spraying, For the spraying flow factor, For the distribution factor of smoke and dust; Step S3: Before adjusting the conveying spacing, set a statistical time, collect the cumulative time of the spray gun spraying work within the statistical time and calculate the duty cycle coefficient, and detect the placement vibration data of the steel bars to be sprayed. In step S3, before adjusting the conveying distance, a preset statistical time is set, and the cumulative time for the spray gun to perform spraying work is obtained from the spray gun operation database within the preset statistical time. The ratio of the cumulative duration to the preset statistical time is used as the duty cycle coefficient; The coordinate points of the continuous position of the steel bar to be sprayed after it is placed are collected by a laser displacement sensor. The difference between the coordinates of each position and the preset placement position is calculated using the Euclidean distance algorithm, and this difference is used as the placement position offset value. In step S3, the maximum value of the placement position offset is taken as the shaking offset amplitude of the steel bar to be sprayed; Within a preset statistical time period, the fluctuation of the placement position is calculated based on the shaking offset amplitude of each steel bar to be sprayed; The fluctuation in the placement position is used as the placement vibration data for the steel bars to be sprayed; Step S4: Evaluate the rebar conveying characteristics by combining the duty cycle coefficient and placement jitter data, and correct the conveying spacing according to the rebar conveying characteristics. After correction, collect the peak dust concentration of the marked dust sensor to determine whether to make a second adjustment to the conveying spacing. In step S4, the duty cycle coefficient and the placement jitter data are standardized to obtain the duty cycle factor and the placement jitter factor. The characteristics of rebar delivery are calculated based on duty cycle factor and placement jitter factor; The product of the steel bar conveying characteristics and the preset balance coefficient is used as the conveying spacing adjustment index; The adjusted conveying spacing is the product of the conveying spacing adjustment index and the current conveying spacing of the steel bars to be sprayed.

2. The automatic placement and conveying control method for a steel bar thermal spraying production line according to claim 1, characterized in that: In step S1, the smoke and dust database is accessed to retrieve the flue flow direction data corresponding to the spraying operation area; The dust database is a structured data collection used to store dust flow parameters, flow field change records, and historical concentration data at various monitoring locations within the spraying operation area; The flue gas flow direction data includes the mainstream angle of the flue gas and the average flow velocity of the flue gas. The mainstream angle of the flue gas is the average value of the instantaneous flow direction angles of all flow velocity monitoring positions monitored by the flow direction monitoring unit. The average velocity of the smoke and dust is the average value of the instantaneous velocity measured by the flow direction monitoring unit within a fixed monitoring period; The flow direction monitoring unit has several fixed installation points along the main flow direction in the spraying operation area, and each installation point is a flow velocity monitoring position.

3. The automatic placement and conveying control method for a steel bar thermal spraying production line according to claim 2, characterized in that: In step S1, when dividing the spraying operation area into sections based on the flue flow direction data, the main axis direction of the flue flow within the spraying operation area is determined by the main flue flow direction angle. All velocity monitoring positions are arranged sequentially along the main axis of the spraying operation area, and the difference in average dust velocity between the velocity monitoring position and the adjacent previous velocity monitoring position is calculated point by point. When the average velocity difference of the smoke and dust reaches or exceeds the preset velocity change threshold, the spatial location corresponding to the velocity monitoring location is defined as the segment boundary, forming the upstream segment, the midstream segment and the downstream segment in sequence. The dust sensors deployed in each section are invoked and section marking is executed. The dust sensors are online dust concentration detection devices pre-installed in the spraying operation area. Once the steel bars to be sprayed enter the spraying operation area, the marked dust sensor in the corresponding section is activated to collect the mass concentration of suspended particulate matter in a unit volume of air to obtain dust concentration data.

4. The automatic placement and conveying control method for a steel bar thermal spraying production line according to claim 1, characterized in that: In step S2, the spraying quality characteristics are compared with the preset spraying quality threshold: When the spraying quality and efficiency characteristics are greater than or equal to the preset spraying quality and efficiency threshold, it is determined that there is no need to adjust the conveying spacing of the steel bars to be sprayed. When the spraying quality characteristics are less than the preset spraying quality threshold, it is determined that the conveying spacing of the steel bars to be sprayed needs to be adjusted to improve the spraying environment.

5. The automatic placement and conveying control method for a steel bar thermal spraying production line according to claim 1, characterized in that: In step S4, after correcting the conveying distance, a preset sampling period is set, and the dust concentration data of the marked dust sensor is obtained within the preset sampling period. The maximum value of the dust concentration data is taken as the peak dust concentration. Access the historical database to retrieve the concentration peak reference, which refers to the reference value of the peak concentration of smoke and dust in the spraying operation area obtained based on historical production data statistics; If the peak concentration of smoke and dust is greater than the peak concentration benchmark, then it is determined that the conveying spacing should be adjusted a second time. Conversely, if the conditions are not met, it is determined that no further adjustment of the conveying spacing will be made.

6. The automatic placement and conveying control method for a steel bar thermal spraying production line according to claim 5, characterized in that: In step S4, when the conveying distance is adjusted for the second time, the difference between the peak dust concentration and the peak concentration reference is used as the concentration offset; the gain adjustment index is calculated based on the concentration offset, and the product of the current conveying distance and the gain adjustment index is used as the conveying distance after the second adjustment.

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