Device for rust removal and corrosion prevention of prefabricated pipe pile head

Abstract

The invention discloses a device for rust removal and corrosion prevention of a prefabricated pipe pile head, and belongs to the technical field of building construction machinery. The device aims at solving the problems that manual rust removal and corrosion prevention are low in efficiency and unstable in quality. The device comprises a steel brush, a telescopic rod, a motor, a chain, a steel brush driving motor, a transmission shaft, a spray head, an anti-corrosion coating box, a coating conveying pipeline, a valve, a supercharging device, a hollow cylindrical sleeve, a switch control system and a conveying line. The steel brush driving motor drives the steel brush to rotate through a transmission shaft. All the components are integrated in the hollow cylindrical sleeve, and the automatic operation of rust removal and spraying is achieved through a switch control system. The device is mainly used for mechanical rust removal and anti-corrosion treatment of the prefabricated pipe pile head, the construction efficiency can be effectively improved, and the operation quality can be guaranteed.

Description

Technical Field

[0001] This invention belongs to the field of construction machinery technology, specifically relating to a device for rust removal and corrosion prevention of precast pipe pile heads. Background Technology

[0002] In construction projects such as photovoltaic power generation and industrial plants, precast concrete pipe piles are widely used as foundations. To improve the durability of the piles, the pile heads need to be derusted and coated with anti-corrosion paint. Currently, this process mainly relies on manual labor.

[0003] Manual rust removal typically uses handheld wire brushes or electric angle grinders, which suffers from low efficiency. Due to the large number and dispersed distribution of pipe piles, treating them one by one prolongs the overall construction period. Furthermore, workers struggle to maintain consistent operating force and angle, leading to uneven rust removal, with some areas retaining loose rust while others are over-grinded. The quality of rust removal largely depends on the worker's skill and sense of responsibility, making it difficult to guarantee consistent quality.

[0004] In the application of anti-corrosion coatings, manual brushing or roller application presents challenges in controlling the uniformity of coating distribution. Manual brushing easily leads to uneven coating thickness, affecting the reliability of the anti-corrosion effect. Furthermore, coating drips are prone to occur during application, resulting in material waste and potential soil pollution. This reduced coating utilization indirectly increases material costs.

[0005] The limitations of manual operation described above result in problems such as fluctuating pass rates, high overall costs, and limited construction efficiency in pile head rust removal and corrosion protection construction. Attempts to replace manual labor with mechanized equipment have encountered several technical difficulties. For example, simply combining rust removal and corrosion protection functions can easily lead to complex equipment structures and cumbersome operation. In the transition between rust removal and spraying functions, if the switching is not smooth, it may lead to secondary contamination of the already rusted surface, or poor adhesion between the paint and the remaining rust layer. Furthermore, how to effectively adapt the equipment to different diameter pipe pile heads and maintain stable operating results is also a challenge that needs to be addressed. Summary of the Invention

[0006] One object of the present invention is to solve at least the above-mentioned problems and / or defects, and to provide at least the advantages described below.

[0007] One objective of this invention is to solve the problems of low efficiency, unstable quality, and insufficient automation caused by manual operation in the existing precast pipe pile head anti-corrosion and rust removal construction.

[0008] One objective of this invention is to solve the problem of interference between the steel brush and the spray head that may occur when the device switches between rust removal and spraying processes because the telescopic rod is not fully retracted.

[0009] An object of the present application is to solve the problem that the timing of completing the rust removal operation is difficult to accurately determine.

[0010] An object of the present application is to solve the problem that the pile head is impacted or the positioning is inaccurate due to improper speed control during the extension of the steel brush.

[0011] An object of the present application is to solve the problem of energy waste and action conflict that may occur during the cooperative operation of multiple actuators.

[0012] An object of the present application is to solve the problem of poor adaptability caused by manual setting or timing control of the extension position of the telescopic rod.

[0013] An object of the present application is to solve the problem of insufficient reliability of single position signal determination for determining the safety state of spraying.

[0014] An object of the present application is to solve the problem of insufficient adaptability of the fixed current threshold method in dealing with different rust conditions.

[0015] An object of the present application is to solve the adaptability problem of the fixed position switching speed strategy under different pile position deviation conditions.

[0016] An object of the present application is to solve the safety hazard problem caused by the failure of electrical interlocking when the main control system fails.

[0017] The utility model provides a device for prefabricated pipe pile head rust removal anticorrosion, including steel brush, telescopic rod, motor, chain, steel brush drive motor, transmission shaft, shower nozzle, anticorrosive paint tank, coating delivery pipeline, valve, booster, hollow cylindrical sleeve, switch control system and transmission line, the motor, steel brush drive motor, anticorrosive paint tank and switch control system fixed mounting on the hollow cylindrical sleeve, the telescopic rod can move and is passed the lateral wall of the hollow cylindrical sleeve, the motor, the chain and steel brush drive motor are arranged in the outside of the hollow cylindrical sleeve, the rear end of telescopic rod is connected with the chain, the motor is engaged with the chain through the chain wheel, is used for driving telescopic rod to stretch out and retract, steel brush drive motor is connected with the rear end of transmission shaft, transmission shaft is rotatably passed in the inside of telescopic rod, steel brush is arranged in the inside for the hollow cylindrical sleeve, fixed mounting is at the front end of transmission shaft, is driven rotation by steel brush drive motor through transmission shaft, the shower nozzle is arranged in the inside of the hollow cylindrical sleeve, the inside of anticorrosive paint tank is equipped with the booster, and is connected with the shower nozzle through the coating delivery pipeline, and the coating delivery pipeline and shower nozzle are equipped with the valve at the junction, the switch control system is electrically connected with the motor, steel brush drive motor and the booster through the transmission line, the switch control system is configured as: in the rust removal stage, starts the motor to drive telescopic rod to stretch out, starts steel brush drive motor to drive steel brush to rotate simultaneously, makes steel brush contact pile head to carry out rust removal operation, after rust removal is completed, controls telescopic rod to retract steel brush, and stops steel brush drive motor, in the spraying stage, starts the booster and opens the valve, carries out the spraying operation of anticorrosive paint.

[0018] Preferably, the device for prefabricated pipe pile head rust removal anticorrosion further comprises a position sensor; the position sensor is a limit switch; the limit switch is fixedly installed on the inner wall of the hollow cylindrical sleeve, and its triggering position corresponds to the physical position when the telescopic rod is fully retracted; the switch control system is electrically connected with the limit switch and is configured to determine that the telescopic rod is in a safe state when the limit switch is triggered, and accordingly trigger the start of the booster and the opening of the valve.

[0019] Preferably, the device for prefabricated pipe pile head rust removal anticorrosion further comprises a current detection unit, which is connected in series in the power supply circuit of the steel brush drive motor for real-time detection of its working current; the switch control system is electrically connected with the current detection unit and is configured to determine that rust removal is complete when the working current of the steel brush drive motor decreases and stabilizes within a preset threshold range during the rust removal stage, and then perform the operation of controlling the telescopic rod to retract.

[0020] Preferably, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured to control the motor at segmented speeds: during the extension process of the rust removal stage, the telescopic rod is first controlled to approach the pile head quickly at a first speed, and then switched to a second speed to extend slowly just before contacting the pile head, until the steel brush contacts the pile head and reaches the preset contact pressure.

[0021] Preferably, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured to execute the following interlocking and energy management logic: a) When the spraying stage is started, the power supply circuit between the motor and the steel brush drive motor is automatically cut off; b) The start of the steel brush drive motor is conditional upon the extension rod being in the extended position; c) The start of the spraying stage is conditional upon the simultaneous retraction of the extension rod and the stopping of the steel brush drive motor.

[0022] Preferably, the device for rust removal and corrosion prevention of precast pipe pile heads further includes a displacement sensor; the displacement sensor is disposed inside the hollow cylindrical sleeve and is used to detect the extension displacement of the telescopic rod in real time; the switch control system is electrically connected to the displacement sensor and is configured to: during the rust removal stage, control the telescopic rod to stop extending at a preset rust removal position based on the displacement signal fed back by the displacement sensor.

[0023] Preferably, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured such that the start of the spraying stage must simultaneously meet the following two conditions: (1) receiving a signal that the limit switch is triggered; (2) the steel brush drive motor has stopped running for a preset delay time; the switch control system will only trigger the start of the pressurization device and the opening of the valve after simultaneously meeting the above conditions.

[0024] Preferably, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured to: calculate the rate of change of the working current of the steel brush drive motor in real time; the operation of determining that rust removal is complete needs to simultaneously meet the following two conditions: (a) the working current decreases and stabilizes within a preset threshold range; (b) the rate of change of the working current is lower than a preset rate threshold.

[0025] Preferably, the device for rust removal and corrosion prevention of precast pipe pile heads further includes a displacement sensor for real-time detection of the extension displacement of the telescopic rod; the switch control system is electrically connected to the displacement sensor and is configured to: during the extension process of the rust removal stage, based on the feedback from the displacement sensor, when the estimated distance between the steel brush and the pile head surface reaches a preset safety buffer distance, control the telescopic rod to switch from the first speed to the second speed.

[0026] Preferably, the device for rust removal and corrosion prevention of precast pipe pile heads further includes an independent safety monitoring unit; the safety monitoring unit is electrically connected to the control circuit of the position sensor and the pressurizing device; the safety monitoring unit is configured to continuously monitor the signal of the position sensor, and when the telescopic rod is not in the retracted position, regardless of what command the switch control system issues, the safety monitoring unit will forcibly keep the power supply circuit of the pressurizing device in the disconnected state.

[0027] The present invention has at least the following beneficial effects: This invention integrates rust removal and spraying functions into a single device, achieving mechanized processing of precast pipe pile heads. The device independently drives the rotation of the steel brush and the movement of the spray nozzle, automatically completing the continuous processes of rust removal and spraying, reducing the labor intensity of manual operation. This integrated design reduces process changeover time, improves construction efficiency, and avoids the problem of inconsistent quality caused by manual operation, resulting in more uniform and reliable pile head treatment quality.

[0028] This invention establishes a physical position-based safety interlock mechanism by setting a limit switch to detect the position of the telescopic rod. This design ensures that the spraying function can only be activated after the steel brush has been fully retracted to the safe position, effectively preventing mechanical interference between the steel brush and the spray head during operation. This position detection method improves the safety of equipment operation, avoids equipment damage caused by misoperation, and ensures the smooth progress of spraying operations.

[0029] This invention provides an intelligent judgment method based on load characteristics to determine the completion of rust removal by monitoring the motor's operating current. By monitoring changes in the operating current of the steel brush drive motor in real time, the completion status of the rust removal operation can be accurately identified. This method reduces reliance on manual experience and judgment, achieves automated control of the rust removal process, improves operational accuracy, and avoids over-removal or incomplete rust removal.

[0030] This invention employs a segmented speed control strategy to achieve smooth control of the steel brush extension process. By controlling the brush to approach rapidly and then make contact slowly, both operational efficiency and impact upon contact between the steel brush and the pile head are ensured. This control method extends the equipment's service life, improves positioning accuracy, and ensures stable contact between the steel brush and the pile head surface, providing a solid foundation for subsequent rust removal operations.

[0031] This invention establishes a collaborative working mechanism among multiple actuators by creating electrical interlocking logic. This design clearly defines the start-stop sequence and operational state relationships of each motor and actuator, effectively preventing action conflicts. The interlocking logic improves the coordination of system operation, reduces the risk of misoperation, and minimizes unnecessary energy consumption through reasonable energy management.

[0032] This invention achieves precise control of the extension position by detecting the travel of the telescopic rod using a displacement sensor. Employing a closed-loop control method with displacement feedback, the device can adapt to the rust removal needs of pipe piles of different specifications. This control method improves the versatility and adaptability of the equipment, ensures the accuracy of the rust removal position, and avoids operational quality problems caused by inaccurate positioning.

[0033] This invention enhances the safety and reliability of the spraying stage by setting composite safety conditions. Combining position signals with motor stop delay judgments creates a more comprehensive safety assessment mechanism. This design ensures that spraying only resumes after the steel brush has completely stopped and retracted, effectively preventing paint splattering caused by inertial rotation and further improving operational safety.

[0034] This invention improves the adaptability of rust removal completion determination by introducing a current change rate criterion. The dual judgment condition combining the absolute value of the current and its change rate allows the system to better adapt to different rusting conditions. This method enhances the system's ability to identify dynamic conditions, improves judgment accuracy, and makes rust removal operations more aligned with actual working conditions.

[0035] This invention achieves adaptive buffer control by dynamically determining the speed switching point. Based on the estimated distance calculated in real time by displacement sensors, the timing of speed switching is dynamically adjusted, enabling the device to adapt to different pile position deviations. This control method optimizes working efficiency and improves the system's adaptability to different working conditions while ensuring no impact.

[0036] This invention establishes a hardware-level security protection mechanism by adding an independent safety monitoring unit. This unit operates in parallel with the main control system and can directly cut off power to high-risk actuators in the event of a main control system failure. This design provides additional safety assurance, improves the system's fail-safe level, and ensures the safe operation of the equipment under abnormal conditions.

[0037] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the device for rust removal and corrosion prevention of precast pipe pile heads provided by the present invention.

[0039] Figure 2 This is a schematic diagram of the steel brush provided by the present invention. Detailed Implementation

[0040] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0041] like Figure 1 and Figure 2 As shown, this invention provides a device for rust removal and corrosion prevention of precast pipe pile heads, including a steel brush 1, a telescopic rod 8, a motor 15, a chain 3, a steel brush drive motor 13, a transmission shaft 7, a nozzle 6, an anti-corrosion coating tank 5, a coating delivery pipeline 4, valves, a pressurizing device 9, a hollow cylindrical sleeve 10, a switch control system 11, and a transmission line 12; the motor, the steel brush drive motor, the anti-corrosion coating tank, and the switch control system are fixedly installed on the hollow cylindrical sleeve; the telescopic rod movably passes through the side wall of the hollow cylindrical sleeve, and the motor, the chain, and the steel brush drive motor are located outside the hollow cylindrical sleeve, with the rear end of the telescopic rod connected to the chain; the motor meshes with the chain through a sprocket to drive the telescopic rod to extend and retract; the steel brush drive motor is connected to the rear end of the transmission shaft; the transmission shaft rotatably passes through the interior of the telescopic rod; the steel brush is installed... The device is placed inside the hollow cylindrical sleeve and fixedly installed at the front end of the drive shaft. It is driven to rotate by the steel brush drive motor through the drive shaft. The spray head is located inside the hollow cylindrical sleeve. The anti-corrosion coating tank is equipped with the pressurizing device and is connected to the spray head through the coating delivery pipe. The connection between the coating delivery pipe and the spray head is equipped with the valve. The switch control system is electrically connected to the motor, the steel brush drive motor, and the pressurizing device through the transmission line. The switch control system is configured to: in the rust removal stage, start the motor to drive the telescopic rod to extend, and simultaneously start the steel brush drive motor to drive the steel brush to rotate, so that the steel brush contacts the pile head to perform the rust removal operation; after the rust removal is completed, control the telescopic rod to retract the steel brush and stop the steel brush drive motor; in the spraying stage, start the pressurizing device and open the valve to perform the anti-corrosion coating spraying operation.

[0042] Compared to the closest existing technology, this invention provides a more complete mechanized solution. Existing technologies typically involve manual hand-held power tools for rust removal, followed by brush application of anti-corrosion coatings. This method suffers from limitations in construction efficiency due to worker skill levels, difficulty in ensuring uniform rust removal, and challenges in controlling coating thickness. Especially in large-scale photovoltaic power plants and other projects with numerous pipe piles, manual construction is time-consuming and results in poor quality consistency.

[0043] The specific implementation of this invention is as follows: The device adopts a hollow cylindrical sleeve as its main structure, and an electric motor and a steel brush drive motor are fixedly installed inside the sleeve. The electric motor drives the telescopic rod to move linearly through the cooperation of a sprocket and a chain, realizing the extension and retraction of the steel brush. The steel brush drive motor drives the steel brush to rotate through a transmission shaft passing through the telescopic rod. This internal transmission shaft design allows the steel brush to maintain stable rotation during the extension and retraction process.

[0044] During the rust removal stage, the switch control system simultaneously starts the motor and the steel brush drive motor. The telescopic rod drives the rotating steel brush forward until it contacts the surface of the pipe pile head. By controlling the extension length of the telescopic rod and the rotation speed of the steel brush, uniform rust removal is achieved on the pile head surface.

[0045] After rust removal is completed, the telescopic rod retracts the steel brush. The pressurization device is activated, transporting the anti-corrosion coating from the tank to the spray nozzle through the coating delivery pipeline. The spray nozzle then evenly sprays the coating onto the surface of the derusted pile head.

[0046] The switch control system can be implemented using a PLC or embedded microcontroller (such as the STM32 series), and has multiple I / O interfaces and analog signal acquisition functions to receive sensor signals and control each motor and valve.

[0047] This implementation integrates rust removal and spraying functions into a single device, enabling continuous automated operation of both processes. Compared to traditional manual methods, it improves construction efficiency and ensures consistent quality in rust removal and spraying. The device's structural design allows it to adapt to the construction needs of pipe piles of different diameters.

[0048] In use, the device of this invention has a hollow cylindrical sleeve fitted onto the outside of the precast pipe pile head to be treated, with its axis roughly aligned with the axis of the pipe pile. The inner diameter of the sleeve is slightly larger than the outer diameter of the pipe pile, providing installation space for the device and allowing it to adapt to pipe piles of different specifications within a certain range. Both the nozzle and the steel brush are positioned facing inwards towards the pile head surface, thus forming a relatively enclosed working area inside the sleeve. This helps to collect rust-removing dust and reduce paint splatter.

[0049] The specific usage method of the aforementioned integrated rust removal and anti-corrosion device for precast pipe pile heads is as follows: First, install the device onto the pile head requiring rust removal and anti-corrosion. The switch control system starts the motor and the steel brush drive motor, and the telescopic rod extends the rotating steel brush forward. The system intelligently judges the rust removal progress by monitoring the working current of the steel brush drive motor in real time. When the working current decreases and stabilizes within a preset threshold range, the system determines that rust removal is complete, and then controls the telescopic rod to retract the steel brush and stop the steel brush drive motor. Afterward, the switch control system starts the pressurization device and opens the valve, delivering the anti-corrosion coating through the coating delivery pipeline to the nozzle, which then evenly sprays the coating onto the surface of the rust-removed pile head. This device is suitable for projects using precast pipe piles and sites with complex geological conditions. It features a high degree of automation, high efficiency, low labor costs, and stable quality in pile head rust removal and anti-corrosion. The system can improve judgment accuracy by using multiple preset current thresholds or adaptive learning algorithms based on different pile head materials or rust levels.

[0050] The switch control system can be set to automatic mode or manual mode as needed for construction; the motor can be powered by a rechargeable battery or an external power source. The transmission line is a combination of power lines and signal lines for power supply and control signal transmission.

[0051] The above-mentioned automated control process enables seamless and safe operation of rust removal and spraying processes, so as to complete the anti-corrosion and rust removal work of pile heads efficiently and quickly.

[0052] In a preferred embodiment, the device for rust removal and corrosion prevention of precast pipe pile heads further includes a position sensor; the position sensor is a limit switch; the limit switch is fixedly installed on the inner wall of the hollow cylindrical sleeve, and its trigger position corresponds to the physical position of the telescopic rod when it is fully retracted; the switch control system is electrically connected to the limit switch and is configured to: when the limit switch is triggered, determine that the telescopic rod is in a safe state, and accordingly trigger the start of the pressurization device and the opening of the valve.

[0053] Compared to existing technologies that rely on manual observation or simple timed control, this invention provides a more reliable safety control solution. In existing technologies, the switching between rust removal and spraying processes usually relies on the operator's visual judgment or preset time intervals. This method carries the risk of misjudgment, and equipment interference may occur due to the steel brush not being fully retracted.

[0054] In a specific embodiment of the invention, a limit switch is installed on the inner wall of a hollow cylindrical sleeve. The installation position of this switch corresponds to the position when the telescopic rod is fully retracted. When the telescopic rod moves to the fully retracted position, it will press the limit switch, causing a signal change. The switch control system monitors the status of the limit switch in real time, and only after receiving a signal that the limit switch has been triggered will it allow the activation of each actuator in the spraying stage.

[0055] This implementation method ensures safe process switching through physical position detection. Even if the control system malfunctions, the spraying program will not start if the telescopic rod is not fully retracted, thus avoiding the possibility of interference between the rotating steel brush and the spraying mechanism. Compared to methods relying on manual judgment or timed control, this physical position detection-based method offers higher reliability, ensuring the continuous and stable operation of the equipment.

[0056] This implementation method features a simple structure and convenient installation. Limit switches, as mature industrial components, offer good durability and stability, making them suitable for long-term use in construction site environments. This design achieves a safe connection between the rust removal and spraying processes, improving the automation and safety of the entire system.

[0057] In a preferred embodiment, the device for rust removal and corrosion prevention of precast pipe pile heads further includes a current detection unit connected in series in the power supply circuit of the steel brush drive motor for real-time detection of its operating current; the switch control system is electrically connected to the current detection unit and is configured to: during the rust removal stage, when the operating current of the steel brush drive motor decreases and stabilizes within a preset threshold range, determine that the rust removal is complete, and then execute the operation of controlling the retraction of the telescopic rod.

[0058] Compared to existing technologies that rely on manual observation or fixed-time control of the rust removal process, this invention provides an intelligent judgment method based on motor load characteristics. In existing technologies, rust removal is typically completed by operators visually judging the degree of rust removal or setting a fixed rust removal time. This method is easily affected by subjective factors and may result in insufficient or excessive rust removal.

[0059] In a specific embodiment of the invention, a current detection unit is connected in series in the power supply circuit of the steel brush drive motor. This unit can monitor the operating current of the motor in real time. During the rust removal operation, when the steel brush comes into contact with the rust layer on the pile head surface, the motor load is large, and the operating current remains at a high level. As the rust layer is gradually removed, the contact resistance between the steel brush and the substrate decreases, the motor load decreases accordingly, and the operating current shows a downward trend.

[0060] The switch control system continuously collects signals from the current detection unit. When it detects that the operating current has continuously decreased from its initial high value and finally stabilized within a preset threshold range, the system determines that the rust removal operation is complete. Subsequently, the control system automatically executes subsequent operation procedures, including stopping the steel brush rotation and retracting the telescopic rod. The threshold range can be set experimentally, for example, between 30% and 50% of the rated current, specifically 5A-8A.

[0061] This implementation method determines the rust removal progress by monitoring real-time load changes of the motor, making it more adaptable to pile heads with varying degrees of rust than methods relying on fixed times or manual observation. For severely rusted pile heads, the system automatically extends the rust removal time to ensure effectiveness; for lightly rusted pile heads, the system shortens the operation time accordingly, improving efficiency. This method reduces reliance on operator experience, making rust removal operations more objective and accurate.

[0062] In a preferred embodiment, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured to control the motor at segmented speeds: during the extension process of the rust removal stage, the telescopic rod is first controlled to approach the pile head quickly at a first speed, and then switched to a second speed to extend slowly just before contacting the pile head, until the steel brush contacts the pile head and reaches a preset contact pressure.

[0063] Compared to existing technologies that use a single speed for rust removal, this invention provides a more stable contact control method. In existing technologies, rust removal devices typically approach the pile head at a constant speed. This operation may cause the steel brush to impact the pile head due to excessive speed, affecting the rust removal effect and equipment lifespan.

[0064] In a specific embodiment of the present invention, the motor is controlled in segments using a switch control system. During the initial stage of rust removal, the control system drives the telescopic rod to extend forward at a relatively high speed, causing the steel brush to quickly approach the pile head. When the system determines that the steel brush is about to contact the pile head surface, it controls the motor to reduce its speed, allowing the telescopic rod to continue extending at a slower speed.

[0065] During the slow extension phase, the system monitors relevant parameters to determine the contact state between the steel brush and the pile head. When a suitable contact pressure is detected between the steel brush and the pile head surface, the control system maintains the current extension state, preserving stable rust removal operating conditions. This contact pressure is indirectly reflected by the load current of the steel brush drive motor; the system maintains the preset contact pressure by keeping this current within a certain range. This initial fast-then-slow speed control method ensures both operational efficiency and smooth contact between the steel brush and the pile head surface. The first speed can be 10-20 mm / s, and the second speed can be 2-5 mm / s.

[0066] Compared to single-speed control, this segmented speed control method effectively avoids equipment impact and improves the stability of rust removal operations. The rapid approach phase shortens the idle travel time, while the slow contact phase ensures the smoothness of the initial operation, providing a good foundation for subsequent rust removal quality. This implementation optimizes the motion process, improving both equipment lifespan and operational quality while maintaining efficiency.

[0067] In a preferred embodiment, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured to execute the following interlocking and energy management logic: a) When the spraying stage is started, the power supply circuit between the motor and the steel brush drive motor is automatically cut off; b) The start of the steel brush drive motor is conditional upon the extension rod being in the extended position; c) The start of the spraying stage is conditional upon the simultaneous retraction of the extension rod and the stopping of the steel brush drive motor.

[0068] Compared to the control methods in existing technologies where each actuator operates independently, this invention provides a coordinated control solution. In existing technologies, rust removal and spraying devices typically employ simple sequential control, lacking a systematic coordination mechanism, which may lead to energy waste or conflicting actions.

[0069] In a specific embodiment of this invention, a complete interlocking and energy management logic is established through a switch control system. During the spraying stage, the system automatically cuts off the power supply circuits to the motor and the brush drive motor to avoid unnecessary energy consumption. The brush drive motor is subject to a precondition for startup; it can only operate when the extension rod is detected, preventing the brush from idling when not in use.

[0070] The system incorporates a composite condition for initiating the spraying stage, requiring that both the telescopic rod retract into place and the steel brush drive motor stop simultaneously. This dual-confirmation mechanism ensures the safety of process transitions. In terms of control logic implementation, the system monitors the status signals of each actuator in real time and performs judgments and controls according to preset interlocking relationships.

[0071] Compared to simple sequential control, this implementation establishes a systematic collaborative working mechanism by creating state associations between actuators. The components maintain both continuity of action and necessary safety isolation. This control method ensures smooth workflow while improving energy efficiency, reducing equipment idling losses, and guaranteeing the long-term stable operation of the equipment.

[0072] In a preferred embodiment, the device for rust removal and corrosion prevention of precast pipe pile heads further includes a displacement sensor; the displacement sensor is disposed inside the hollow cylindrical sleeve and is used to detect the extension displacement of the telescopic rod in real time; the switch control system is electrically connected to the displacement sensor and is configured to: during the rust removal stage, control the telescopic rod to stop extending at a preset rust removal position based on the displacement signal fed back by the displacement sensor.

[0073] Compared with existing control methods that use fixed strokes or manual adjustments, this invention provides a highly adaptable position control scheme. In existing technologies, the extension position of the rust removal device is usually set by mechanical limits or empirical values, which is difficult to adapt to the construction needs of pipe piles of different specifications.

[0074] A specific embodiment of the present invention involves installing a displacement sensor inside a hollow cylindrical sleeve. This sensor can detect the extension displacement of the telescopic rod in real time. During the rust removal operation, the switch control system continuously reads the signal from the displacement sensor to accurately monitor the positional changes of the steel brush relative to the pile head surface.

[0075] When the telescopic rod extends to the preset rust removal position, the control system promptly stops the motor based on feedback signals from the displacement sensor, ensuring the steel brush accurately stops at the target working position. This real-time displacement feedback-based control method allows the device to flexibly adjust the final working position of the steel brush according to different pipe pile specifications and rust removal requirements.

[0076] Compared to methods relying on fixed travel limits, this implementation offers better adaptability. By adjusting the position setpoints in the control system, the same device can be applied to the construction of various pipe pile specifications. The use of displacement sensors improves the accuracy of position control, avoiding position deviations caused by mechanical wear or human error, and ensuring the accuracy and consistency of rust removal operations. This solution improves the versatility and control precision of the device while maintaining a simple and reliable structure.

[0077] In a preferred embodiment, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured such that the start of the spraying stage must simultaneously meet the following two conditions: (1) receiving a signal that the limit switch has been triggered; (2) the steel brush drive motor has stopped running for a preset delay time; the switch control system will only trigger the start of the pressurization device and the opening of the valve after simultaneously meeting the above conditions.

[0078] Compared to existing technologies that rely on a single signal for safety determination, this invention provides a more reliable safety confirmation mechanism. Existing technologies typically determine whether spraying can commence solely through position sensor signals, a method that can lead to paint splattering due to the inertial rotation of the steel brush.

[0079] A specific embodiment of the present invention adds a delay judgment for the motor's stop state. After receiving the trigger signal from the limit switch, the switch control system does not immediately start the spraying program, but simultaneously checks the operating status of the steel brush drive motor. The system needs to confirm that the motor has stopped running and starts timing. Only when the stop time reaches a preset delay value is one of the conditions for starting spraying met. The delay time is typically set to 2-5 seconds to ensure that the steel brush completely stops rotating.

[0080] This delay setting ensures that the steel brush has sufficient time to completely stop rotating, eliminating the possibility of it continuing to rotate due to inertia. The switch control system will only trigger the start of the booster device and the opening of the valve when both the limit switch signal and the motor stop delay are met simultaneously.

[0081] Compared to single-signal determination, this composite condition determination method offers higher safety and reliability. By introducing a time delay factor, the system can fully consider the inertial characteristics of mechanical motion, avoiding potential problems caused by starting the next process before the moving parts have completely stopped. This implementation improves safety without stopping the machine and maintains the continuity of the work process.

[0082] In a preferred embodiment, in the device for rust removal and corrosion prevention of precast pipe pile heads, the switch control system is configured to: calculate the rate of change of the working current of the steel brush drive motor in real time; the operation of determining that rust removal is complete requires the simultaneous fulfillment of the following two conditions: (a) the working current decreases and stabilizes within a preset threshold range; (b) the rate of change of the working current is lower than a preset rate threshold.

[0083] Compared to existing technologies that rely solely on a single current threshold to determine the completion of rust removal, this invention provides a more accurate method for assessment. Existing methods that set a fixed current threshold may lead to misjudgments when dealing with pile heads with varying degrees of rust.

[0084] A specific embodiment of the present invention incorporates the calculation of the current change rate. The switch control system monitors the operating current of the brush-driven motor while simultaneously calculating the change in current per unit time in real time. By continuously acquiring current data, the system calculates the trend and rate of current change.

[0085] During the rust removal process, the control system monitors two parameters simultaneously: first, whether the absolute value of the current decreases and stabilizes within a preset threshold range; and second, whether the rate of change of the current is lower than a preset rate threshold. Only when both conditions are met will the system determine that the rust removal operation is complete and execute subsequent operations.

[0086] This dual-judgment mechanism can more accurately identify the actual state of rust removal operations. When the rust is severe, the current decreases more slowly, and the rate of change index prevents the system from prematurely determining that rust removal is complete. When the rust is mild, the absolute value of the current ensures that the rust removal effect meets requirements. By combining the comprehensive judgment of absolute value and rate of change, the system can adapt to different working conditions and improve the accuracy of rust removal completion determination. This implementation adds dynamic analysis functionality to the original current detection, making the judgment logic more complete.

[0087] In a preferred embodiment, the device for rust removal and corrosion prevention of precast pipe pile heads further includes a displacement sensor for real-time detection of the extension displacement of the telescopic rod; the switch control system is electrically connected to the displacement sensor and is configured to: during the extension process of the rust removal stage, based on the feedback from the displacement sensor, when the estimated distance between the steel brush and the pile head surface reaches a preset safety buffer distance, control the telescopic rod to switch from the first speed to the second speed.

[0088] Compared with the existing technology of controlling speed by switching at a fixed position, the present invention provides an adaptive speed control scheme. In the prior art, the speed switching point is usually preset based on empirical values. When there is a construction deviation in the pile head position, it may cause insufficient buffer distance or reduced efficiency.

[0089] In a specific embodiment of the present invention, real-time feedback from a displacement sensor is added. During the extension process in the rust removal stage, the displacement sensor continuously detects the displacement of the telescopic rod, and the switch control system calculates the estimated distance between the front end of the steel brush and the surface of the pile head in real time based on this displacement data.

[0090] When the system calculates that the distance between the steel brush and the pile head surface reaches a preset safety buffer distance, it controls the motor to switch from a faster first speed to a slower second speed. This safety buffer distance ensures that the telescopic rod has sufficient distance to slowly and smoothly contact the pile head, while avoiding efficiency losses caused by premature switching. Based on the telescopic rod displacement fed back by the displacement sensor and combined with the initial installation position of the device, the system can calculate the estimated distance between the tip of the steel brush and the pile head surface. When this estimated distance reaches a preset safety buffer distance, the system controls the telescopic rod to switch from the first speed to the second speed. The estimated distance is a dynamic distance value calculated based on the displacement sensor reading and the initial installation position of the device. The safety buffer distance is typically set to 10-20 mm. During device installation, the initial position of the telescopic rod can be aligned with the pile head surface through a manual or automatic calibration procedure to ensure the accuracy of the displacement sensor measurement.

[0091] Compared to a fixed-position speed switching method, this real-time distance-based switching strategy can adapt to different pile head positions. Even if there are certain deviations in the installation of the pipe piles, the system can automatically adjust the speed switching timing to always maintain a reasonable buffer distance. This implementation method optimizes work efficiency and improves the adaptability of the device to different construction conditions by dynamically adjusting control parameters while ensuring smooth contact.

[0092] In a preferred embodiment, the device for rust removal and corrosion prevention of precast pipe pile heads further includes an independent safety monitoring unit; the safety monitoring unit is electrically connected to the position sensor and the control circuit of the booster device; the safety monitoring unit is configured to continuously monitor the signal of the position sensor, and when the telescopic rod is not in the retracted position, regardless of what command the switch control system issues, the safety monitoring unit forcibly keeps the power supply circuit of the booster device in the disconnected state.

[0093] Compared to existing technologies that rely entirely on the main control system for safety interlocking, this invention provides a redundant safety protection scheme. Existing technologies rely entirely on the main control system for safety interlocking; if the control system malfunctions, the interlocking function may fail.

[0094] In a specific embodiment of the present invention, an independent safety monitoring unit is added. This unit is separate from the main control system and directly connected to the control loops of the position sensor and the booster device. The safety monitoring unit continuously monitors the signal status of the position sensor and independently determines the safety status. The safety monitoring unit is isolated from the main control system via a relay or optocoupler, and only allows the main system to control the booster device when a safe status is detected.

[0095] When the safety monitoring unit detects that the telescopic boom is not in the retracted position, it will forcibly keep the power supply circuit of the booster device disconnected. This protective action does not depend on the instructions of the main control system; even if the main control system malfunctions or issues an erroneous command, the safety monitoring unit can still ensure that the booster device will not start under dangerous conditions.

[0096] Compared to a single control system, this implementation establishes an independent security layer. The security monitoring unit focuses on the most critical security functions, providing an effective security backup for the main control system through direct hardware-level control. This solution enhances the system's security level without downtime, providing additional protection for the safe operation of equipment under abnormal conditions.

[0097] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. It can be applied to various fields suitable for the present invention. Other modifications can be readily made by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and examples shown and described herein.

Claims

1. A device for rust removal and corrosion prevention of precast pipe pile heads, comprising a steel brush, a telescopic rod, a motor, a chain, a steel brush drive motor, a transmission shaft, a nozzle, an anti-corrosion coating tank, a coating delivery pipeline, valves, a pressurizing device, a hollow cylindrical sleeve, a switch control system, and a transmission line; the motor, the steel brush drive motor, the anti-corrosion coating tank, and the switch control system are fixedly installed on the hollow cylindrical sleeve; the telescopic rod is movably inserted through the side wall of the hollow cylindrical sleeve; the motor, the chain, and the steel brush drive motor are disposed outside the hollow cylindrical sleeve; the rear end of the telescopic rod is connected to the chain; the motor engages with the chain via a sprocket to drive the telescopic rod to extend and retract; the steel brush drive motor is connected to the rear end of the transmission shaft; the transmission shaft... The steel brush is rotatably inserted inside the telescopic rod; the steel brush is disposed inside the hollow cylindrical sleeve and fixedly installed at the front end of the drive shaft, and is driven to rotate by the steel brush drive motor through the drive shaft; the spray head is disposed inside the hollow cylindrical sleeve, the anti-corrosion coating tank is provided with the pressurizing device, and is connected to the spray head through the coating delivery pipe, and the connection between the coating delivery pipe and the spray head is provided with the valve; the switch control system is electrically connected to the motor, the steel brush drive motor and the pressurizing device through the transmission line; the switch control system is configured to: in the rust removal stage, start the motor to drive the telescopic rod to extend, and simultaneously start the steel brush drive motor to drive the steel brush to rotate, so that the steel brush contacts the pile head to perform the rust removal operation; After rust removal is completed, the telescopic rod is retracted to retract the steel brush, and the steel brush drive motor is stopped. During the spraying stage, the pressurization device is activated and the valve is opened to carry out the spraying operation of the anti-corrosion coating.

2. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 1, characterized in that, It also includes a position sensor; the position sensor is a limit switch; the limit switch is fixedly installed on the inner wall of the hollow cylindrical sleeve, and its trigger position corresponds to the physical position of the telescopic rod when it is fully retracted; the switch control system is electrically connected to the limit switch and is configured to: when the limit switch is triggered, determine that the telescopic rod is in a safe state, and accordingly trigger the start of the pressurization device and the opening of the valve.

3. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 2, characterized in that, It also includes a current detection unit, which is connected in series in the power supply circuit of the steel brush drive motor to detect its operating current in real time; the switch control system is electrically connected to the current detection unit and is configured to: during the rust removal stage, when the operating current of the steel brush drive motor decreases and stabilizes within a preset threshold range, determine that the rust removal is complete, and then execute the operation of controlling the telescopic rod to retract.

4. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 3, characterized in that, The switch control system is configured to control the motor at segmented speeds: during the extension process of the rust removal stage, the telescopic rod is first controlled to approach the pile head quickly at a first speed, and then switched to a second speed to extend slowly just before contacting the pile head, until the steel brush contacts the pile head and reaches the preset contact pressure.

5. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 4, characterized in that, The switch control system is configured to execute the following interlocking and energy management logic: a) When the spraying stage is started, the power supply circuit between the motor and the steel brush drive motor is automatically cut off; b) The start of the steel brush drive motor is conditional upon the extension rod being in the extended position; c) The start of the spraying stage is conditional upon the simultaneous retraction of the extension rod and the stop of the steel brush drive motor.

6. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 5, characterized in that, It also includes a displacement sensor; the displacement sensor is disposed inside the hollow cylindrical sleeve and is used to detect the extension displacement of the telescopic rod in real time; the switch control system is electrically connected to the displacement sensor and is configured to: during the rust removal stage, control the telescopic rod to stop extending at a preset rust removal position based on the displacement signal fed back by the displacement sensor.

7. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 2, characterized in that, The switch control system is configured such that the start of the spraying stage must simultaneously meet the following two conditions: (1) receiving a signal that the limit switch has been triggered; (2) the steel brush drive motor has stopped running for a preset delay time; the switch control system will only trigger the start of the booster device and the opening of the valve after the above conditions are met simultaneously.

8. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 3, characterized in that, The switch control system is configured to: calculate the rate of change of the working current of the steel brush drive motor in real time; the operation of determining that rust removal is complete requires the following two conditions to be met simultaneously: (a) the working current decreases and stabilizes within a preset threshold range; (b) the rate of change of the working current is lower than a preset rate threshold.

9. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 4, characterized in that, It also includes a displacement sensor for real-time detection of the extension displacement of the telescopic rod; the switch control system is electrically connected to the displacement sensor and is configured to: during the extension process of the rust removal stage, based on the feedback of the displacement sensor, when the estimated distance between the steel brush and the pile head surface reaches a preset safety buffer distance, control the telescopic rod to switch from the first speed to the second speed.

10. The device for rust removal and corrosion prevention of precast pipe pile heads according to claim 5, characterized in that, It also includes an independent safety monitoring unit; the safety monitoring unit is electrically connected to the control circuit of the position sensor and the booster device; the safety monitoring unit is configured to continuously monitor the signal of the position sensor, and when the telescopic rod is not in the retracted position, regardless of what command the switch control system issues, the safety monitoring unit will forcibly keep the power supply circuit of the booster device in the disconnected state.

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