Multi-stage continuous treatment type steel wire surface coating device and method for high-speed rail sleeper

Abstract

The invention relates to a multistage continuous treatment type steel wire surface coating device for a high-speed rail sleeper and a method thereof, and belongs to the technical field of dynamic control in the continuous production process, the method comprises the following steps: S1, setting a controller, a dynamic overflow coating head, a multi-area infrared drying furnace, a main speed encoder, an outlet speed encoder and an outlet thermodetector, the main speed encoder is arranged on the inlet side, the dynamic overflow coating head and the multi-area infrared drying furnace are sequentially arranged, and the outlet speed encoder and the outlet thermodetector are arranged on the outlet side. When the controller detects that the reference speed of the inlet is changed, the pumping flow of the coating head can be immediately and reversely adjusted; the predictive adjustment can compensate the change of the residence time of the steel wire in the coating head, so that the steel wire can obtain the theoretical coating adhesion amount with uniform thickness in the dynamic speed regulation process of acceleration and deceleration of the steel wire.

Description

Technical Field

[0001] This invention relates to the field of dynamic control of continuous production processes, specifically to a multi-stage continuous processing device and method for coating the surface of steel wire for high-speed railway sleepers. Background Technology

[0002] With the development and construction of the field of dynamic control of continuous production processes, in the typical scenario of surface coating of steel wire for high-speed railway sleepers, the production line needs to frequently perform dynamic speed adjustment operations of acceleration and deceleration, which brings severe challenges to the process.

[0003] In traditional steel wire surface coating production lines, the change in the steel wire's travel speed during acceleration and deceleration leads to variations in the steel wire's residence time in the coating head, resulting in uneven coating adhesion and an inability to maintain a stable coating thickness. Furthermore, the change in travel speed also causes the actual travel speed of the steel wire within the drying oven to be inconsistent, leading to variations in the actual residence time of the steel wire in different heating zones. This results in an imbalance in the theoretically accumulated heat absorption, causing the drying temperature to become uncontrolled and affecting the final product quality and stability.

[0004] Existing control methods are ill-suited to the complex operating conditions of dynamic speed regulation, especially: Coating adhesion control: Traditional control methods cannot predictively adjust the pump flow rate of the coating head, cannot compensate for changes in the residence time of the steel wire in the coating head, and are difficult to ensure that the steel wire obtains a uniform coating adhesion during dynamic speed regulation.

[0005] Drying heat control: Existing technologies have failed to accurately calculate the actual travel speed of the steel wire at each specific location in the drying oven, nor have they established a waveform transmission mechanism that precisely matches the heat adjustment with the actual position of the steel wire micro-element. This dynamic speed correction model logically accepts the inlet reference speed and instantaneous total elastic elongation as input. It assumes that the instantaneous total elastic elongation is linearly distributed throughout the entire process section and calculates the speed gradient accordingly. Overall, the model characterizes the physical law of the dynamic change in the actual travel speed of the steel wire at different positions due to elastic deformation. Its purpose is to calculate the actual travel speed of the steel wire micro-element at each specific position in the multi-zone infrared drying furnace during dynamic speed regulation. Therefore, it is impossible to accurately and dynamically compensate for the drying heat, and it is difficult to maintain the theoretical cumulative heat absorption of the steel wire when the speed changes, so as to achieve appropriate drying treatment.

[0006] Model Adaptability: Existing control models lack the ability to learn and correct inherent system errors autonomously, and cannot effectively compensate for persistent deviations caused by unmodeled factors such as changes in ambient temperature or thermal inertia, resulting in poor process control stability across the entire speed range.

[0007] In summary, traditional continuous production dynamic control technology is difficult to adapt to the dynamic speed regulation process of the steel wire surface coating production line for high-speed railway sleepers, which seriously affects the uniformity of coating thickness and the stability of drying treatment.

[0008] The information disclosed in the background section above 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

[0009] The purpose of this invention is to provide a multi-stage continuous processing device and method for coating the surface of steel wire for high-speed railway sleepers, so as to solve the problems mentioned in the background art.

[0010] The technical solution of the present invention includes: S1. A controller, a dynamic overflow coating head, a multi-zone infrared drying oven, a main speed encoder, an outlet speed encoder, and an outlet temperature measuring instrument are set up, wherein the main speed encoder is located on the inlet side, the dynamic overflow coating head and the multi-zone infrared drying oven are arranged in sequence, and the outlet speed encoder and the outlet temperature measuring instrument are located on the outlet side. S2. The controller reads the inlet reference speed of the main speed encoder to establish a steel wire micro-element queue, and tracks the queue to record the theoretical coating adhesion amount and theoretical cumulative heat absorption. The theoretical coating adhesion amount represents the total amount of coating material that a unit length of steel wire should obtain under the current process conditions, and serves as the reference target value for reverse adjustment of the pumping flow rate of the coating head. The theoretical cumulative heat absorption represents the total energy absorbed by the steel wire micro-element in all independent heating zones from entering the drying oven to the outlet, and serves as the basis for calculating the theoretical outlet temperature. S3. When the controller detects a change in the inlet reference speed, it reverses the pumping flow rate of the dynamic overflow coating head, calculates the instantaneous total elastic elongation based on the speed difference between the inlet reference speed and the outlet drawing speed, and calculates the power correction waveform so that the power correction waveform is transmitted along the multiple independent heating zones of the multi-zone infrared drying oven. S4. When the steel wire element reaches the outlet temperature measuring instrument, the controller reads the actual outlet temperature, compares the actual temperature with the theoretical outlet temperature, and corrects the conversion model in S3 according to the deviation.

[0011] Preferably, in step S3: the controller calculates a dynamic correction speed model based on the inlet reference speed and the instantaneous total elastic elongation, and the transmission speed of the power correction waveform in the independent heating zone matches the dynamic correction speed model.

[0012] Preferably, in step S2: the theoretical coating adhesion amount is calculated based on the pump flow rate and the calculated residence time of the steel wire micro-element in the dynamic overflow coating head; the theoretical cumulative heat absorption is calculated based on the heating power and the calculated residence time of the steel wire micro-element in the independent heating zone and then superimposed.

[0013] Preferably, in step S4: the deviation is the persistent deviation between the actual outlet temperature and the theoretical outlet temperature, and the controller automatically corrects the conversion model used in S3 to calculate the power correction waveform.

[0014] Preferably, the dynamic overflow coating head includes a coating chamber and a variable frequency peristaltic pump, and the two ends of the coating chamber are provided with non-contact air seal devices.

[0015] Preferably, the interior of the multi-zone infrared drying oven is divided into ten independent heating zones along the direction of the steel wire travel.

[0016] Preferably, the main speed encoder and the outlet speed encoder are high-resolution photoelectric encoders; the outlet temperature measuring instrument is a non-contact pyrometer.

[0017] A multi-stage continuous processing steel wire surface coating device for high-speed railway sleepers includes: Dynamic overflow coating head; A multi-zone infrared drying oven is arranged along the steel wire travel path on the outlet side of the dynamic overflow coating head, and the multi-zone infrared drying oven includes multiple independent heating zones; The main speed encoder is located on the inlet side of the dynamic overflow coating head; An exit speed encoder is installed on the exit side of the multi-zone infrared drying oven; An outlet temperature measuring instrument is installed on the outlet side of the multi-zone infrared drying oven; The controller is electrically connected to the dynamic overflow coating head, the multi-zone infrared drying oven, the main speed encoder, the outlet speed encoder, and the outlet temperature measuring instrument.

[0018] Preferably, the dynamic overflow coating head includes a variable frequency peristaltic pump and a coating chamber, the coating chamber being used to contain coating liquid, and the variable frequency peristaltic pump being used to pump coating liquid into the coating chamber.

[0019] Preferably, the controller is further configured to establish a wire micro-element queue, which is used to logically divide continuously moving wires into virtual wire segments with independent process state data.

[0020] This invention provides an improved multi-stage continuous processing device and method for coating the surface of steel wire for high-speed railway sleepers, which has the following improvements and advantages compared with the prior art: 1. When the controller detects a change in the inlet reference speed, the present invention can immediately reverse the pumping flow rate of the coating head; this predictive adjustment can compensate for the change in the residence time of the steel wire in the coating head, thereby ensuring that the steel wire obtains a theoretical coating adhesion amount with uniform thickness during the dynamic speed regulation process of steel wire acceleration and deceleration. 2. This scheme introduces a dynamic correction speed model based on the instantaneous total elastic elongation. This model calculates the actual travel speed of the steel wire micro-element at each specific position in the drying oven. This waveform transmission mechanism ensures that the adjustment of drying heat can be accurately applied to the corresponding steel wire micro-element, compensating for the change in actual residence time caused by the elastic deformation of the steel wire. By adjusting the power of each independent heating zone, the product of the new heating power and the new calculated residence time is approximately equal to the original reference value. Thus, during the dynamic speed regulation process, the theoretical cumulative heat absorption of the steel wire is kept stable, achieving appropriate drying treatment. 3. The controller can detect persistent deviations between the actual outlet temperature and the theoretical outlet temperature. Such persistent deviations indicate that the conversion model used for calculation in S3 itself has inherent systematic errors, such as unmodeled ambient temperature changes or thermal inertia. Once persistent deviations are identified, the controller will automatically correct the conversion model based on the proportional-integral control algorithm. This method ensures that the control model can learn autonomously and compensate for unmodeled factors, making it closer to the actual physical process, thereby improving the stability of process control across the entire speed range. Attached Figure Description

[0021] The present invention will be further explained below with reference to the accompanying drawings and embodiments: Figure 1 This is a schematic diagram of the overall structure of the device; Figure 2 This is a structural diagram of the wire feeding frame, traction straightening machine, and cleaning tank; Figure 3 This is a structural schematic diagram of a dynamic overflow coating head, a multi-zone infrared drying oven, and a horizontal wire drawing machine; Figure 4 This is a schematic diagram of the connection structure between a multi-zone infrared drying oven and a horizontal wire drawing machine; Figure 5 This is a schematic diagram of the process flow of the method of the present invention.

[0022] In the diagram: 710, Main speed encoder; 300, Cleaning tank; 400, Dynamic overflow coating head; 410, Coating chamber; 420, Variable frequency peristaltic pump; 500, Multi-zone infrared drying oven; 510, Oven body; 520, Independent heating zone; 720, Outlet speed encoder; 730, Outlet thermometer; 740, Non-contact pyrometer; 800, Controller. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0024] Example 1 Please see Figure 1-5 This invention provides a multi-stage continuous processing method for coating the surface of steel wire for high-speed railway sleepers, comprising: S1. A controller 800, a dynamic overflow coating head 400, a multi-zone infrared drying oven 500, a main speed encoder 710, an outlet speed encoder 720, and an outlet temperature measuring instrument 730 are set up. The main speed encoder 710 is located on the inlet side, the dynamic overflow coating head 400 and the multi-zone infrared drying oven 500 are set up in sequence, and the outlet speed encoder 720 and the outlet temperature measuring instrument 730 are located on the outlet side. S2. The controller 800 reads the inlet reference speed of the main speed encoder 710 to establish a steel wire micro-element queue, and tracks the queue to record the theoretical coating adhesion amount and the theoretical cumulative heat absorption. The theoretical coating adhesion amount represents the total amount of coating material that a unit length of steel wire should obtain under the current process conditions, and serves as the reference target value for reverse adjustment of the pumping flow rate of the coating head. The theoretical cumulative heat absorption represents the total energy absorbed by the steel wire micro-element in all independent heating zones 520 from entering the drying oven to the outlet, and serves as the basis for calculating the theoretical outlet temperature. S3. When the controller 800 detects a change in the inlet reference speed, it reverses the pumping flow rate of the dynamic overflow coating head 400, and calculates the instantaneous total elastic elongation based on the speed difference between the inlet reference speed and the outlet drawing speed, and calculates the power correction waveform so that the power correction waveform is transmitted along the multiple independent heating zones 520 of the multi-zone infrared drying oven 500. Instantaneous total elastic elongation is a dynamically quantified physical index used to characterize the degree of total elastic deformation of the steel wire between the coating head inlet and the drying furnace outlet. It is the core input for calculating the dynamic correction speed model, thereby determining the transmission speed of the power correction waveform and the heating power amplitude in the drying furnace. S4. When the wire element reaches the outlet temperature measuring instrument 730, the controller 800 reads the actual outlet temperature, compares the actual and theoretical outlet temperatures, and corrects the conversion model of S3 based on the deviation.

[0025] In one embodiment of the present invention, a multi-stage continuous processing steel wire surface coating control method is provided to address the technical problems of uneven coating adhesion and uncontrolled drying temperature caused by changes in the steel wire travel speed during acceleration and deceleration in existing steel wire coating production lines. This method, through step S1, configures the basic hardware required for control, including a controller 800 (e.g., a Siemens S7-1500 PLC) as the data processing core, a dynamic overflow coating head 400 for coating, a multi-zone infrared drying oven 500 for drying, and a main speed encoder 710, an outlet speed encoder 720, and an outlet temperature sensor 730 for status monitoring. The physical layout of the hardware forms the basis of the process flow. The controller 800 executes step S2, establishing a wire micro-element queue by reading the inlet reference speed from the main speed encoder 710. This wire micro-element queue is a data structure built within the controller 800, logically dividing the continuous physical wire into a series of traceable data segments. The controller 800 can track the theoretical coating adhesion amount and theoretical cumulative heat absorption of each micro-element segment, providing a data foundation for subsequent precise control. When the wire speed changes during production, step S3 is initiated. The controller 800 detects a change in the inlet reference speed and immediately adjusts the pumping flow rate of the dynamic overflow coating head 400 in reverse, for example, increasing the flow rate when the speed increases and decreasing the flow rate when the speed decreases. The purpose is to compensate for changes in the residence time of the wire in the coating head and maintain a stable coating adhesion amount. Simultaneously, the controller 800 calculates the instantaneous total elastic elongation based on the speed difference between the inlet reference speed and the outlet drawing speed, and calculates the power correction waveform accordingly, allowing this power correction waveform to be transmitted within the multiple independent heating zones 520 of the multi-zone infrared drying oven 500.

[0026] The logic for calculating the instantaneous total elastic elongation is as follows: Step 1: The controller 800 reads the inlet reference speed in real time. and export speed Step 2: Calculate the speed difference between the two. Step 3: Calculate the instantaneous total elastic elongation based on the preset material elasticity model or calibration coefficient K. ; This process involves proactive adjustments to ensure that the drying heat matches the state of the steel wire after speed changes. In step S4, when the steel wire element passes through the outlet temperature sensor 730, the controller 800 reads the actual outlet temperature and compares it with the theoretical outlet temperature recorded by that element. If a deviation exists, the controller 800 corrects the conversion model used for calculation in S3. This method, through the tracking in S2, the pre-adjustment in S3, and the correction in S4, works together to ensure that the steel wire achieves a uniform coating thickness and suitable drying treatment even during dynamic speed regulation.

[0027] In step S3: the controller 800 calculates a dynamic correction speed model based on the inlet reference speed and the instantaneous total elastic elongation. The transmission speed of the power correction waveform in the independent heating zone 520 is matched with the dynamic correction speed model.

[0028] In step S3, to make the transmission of the power correction waveform more accurate, the controller 800 performs a specific calculation. Based on the acquired inlet reference speed and the calculated instantaneous total elastic elongation, the controller 800 calculates a dynamic correction speed model. The purpose of introducing the instantaneous total elastic elongation is to address a physical phenomenon: when the steel wire is stretched, accelerated, compressed, or decelerated, its actual physical travel speed at different positions inside the drying oven is not constant, but differs from the inlet reference speed. The function of this dynamic correction speed model is to calculate the actual travel speed of the steel wire element at each specific position inside the drying oven.

[0029] One calculation logic of the controller 800 is as follows: the instantaneous total elastic elongation, for example, a stretch of 0.5%, is assumed to be linearly distributed over the entire process section length from the inlet of the dynamic overflow coating head 400 to the outlet of the multi-zone infrared drying oven 500; based on this assumption of linear distribution, the controller 800 can calculate the velocity gradient, which describes the rate of increase of the wire velocity along its travel path; the controller 800 applies this velocity gradient to the inlet reference velocity to deduce the instantaneous true velocity of the wire element as it enters each of the ten independent heating zones 520; this set, for example, ten path-increasing, corrected velocity values, constitutes the dynamically corrected velocity model, which is used for the transmission matching of the power correction waveform in the subsequent S3 step.

[0030] Therefore, the transmission speed of the power correction waveform in the independent heating zone 520 is no longer based on a constant inlet reference speed, but is matched with the actual travel speed of the wire micro-element calculated by this dynamic correction speed model. In this way, when the actual speed of the wire in the later section of the drying oven is faster than that in the earlier section due to elastic deformation, the transmission speed of the power correction waveform in the later section will also be accelerated accordingly. This ensures that the adjustment of heating power can be accurately applied to the corresponding wire micro-element, compensates for the residence time change caused by elastic deformation, and improves the accuracy of drying temperature control.

[0031] In step S2: the theoretical coating adhesion amount is calculated based on the pump flow rate and the calculated residence time of the steel wire micro-element in the dynamic overflow coating head 400; the theoretical cumulative heat absorption is calculated based on the heating power and the calculated residence time of the steel wire micro-element in the independent heating zone 520 and then superimposed.

[0032] In step S2, to track the process status of the wire micro-element queue, the controller 800 needs to calculate two key theoretical values. The calculation logic for the theoretical coating adhesion amount is as follows: when the wire micro-element logically enters the dynamic overflow coating head 400, the controller 800 records the pumping flow command sent to the dynamic overflow coating head 400 at this moment, and combines it with the calculated residence time derived from the dynamic correction speed model based on the wire micro-element's length and current speed, and the two together calculate the coating amount that the wire micro-element should obtain. The calculation logic for the theoretical cumulative heat absorption is as follows: when the logical position of the wire micro-element enters the first independent heating zone 520 of the multi-zone infrared drying oven 500, the controller 800 records the heating power of that zone at this moment, and combines it with the calculated residence time of the micro-element in that zone to calculate the heat absorbed; when it enters the second independent heating zone 520, this calculation is performed again, and the obtained heat value is added to the data object of the micro-element. This process is repeated as the micro-element passes through all independent heating zones 520 in sequence. Furthermore, the conversion model in S3 refers to a preset benchmark process database. This database, such as a lookup table or function, stores the benchmark heating power required for each of the ten independent heating zones 520 to reach the target drying temperature under different stable inlet benchmark speeds. When step S3 is triggered, the controller 800 first obtains the benchmark heating power before the speed change from the conversion model. Subsequently, the controller 800 calls the dynamic correction speed model calculated in Example 2 to obtain the new calculated residence time of the wire element in each independent heating zone 520. The logic of the controller 800 in calculating the power correction waveform at this time is: adjusting the heating power of each independent heating zone 520 so that the product of the new heating power value and the new calculated residence time is approximately equal to, or equal to, the product of the original benchmark heating power and the original calculated residence time of that zone under a certain compensation coefficient. This set of ten new power setting values ​​obtained through reverse compensation calculation constitutes the power correction waveform.

[0033] The logic for calculating the power correction waveform is as follows: Step 1: Controller 800 obtains the reference heating power before the speed change from the reference process database. and the original calculated residence time Step 2: Based on the dynamically corrected velocity model, obtain the new calculated residence time of the wire micro-element in each heating zone. Step 3: Calculate the new heating power required for each independent heating zone 520. , making Approximately equal to This new set of power settings is the power correction waveform. In this way, the controller 800 records the theoretical coating adhesion amount and the continuously accumulating theoretical heat absorption for each wire micro-element. These data serve as the basis for the judgment and correction in steps S3 and S4.

[0034] In step S4: the deviation is the continuous deviation between the actual outlet temperature and the theoretical outlet temperature. The controller 800 automatically corrects the conversion model used in S3 to calculate the power correction waveform.

[0035] In step S4, to enable the control method to adapt to unmodeled factors, such as changes in ambient temperature or thermal inertia, the controller 800 is equipped with a correction capability. When the controller 800 compares the actual outlet temperature with the theoretical outlet temperature, it focuses on whether the deviation is a persistent deviation. A persistent deviation, for example, in multiple consecutive accelerations, where the actual outlet temperature is systematically lower than the theoretical outlet temperature, indicates that the conversion model used in S3 to calculate the power correction waveform itself has an inherent error. Once such a persistent deviation is identified, the controller 800 will automatically correct the conversion model used in S3 to calculate the power correction waveform. For example, the controller 800 may adjust a coefficient in the model so that the overall power amplitude of the calculated power correction waveform will be slightly increased in subsequent accelerations. The specific logic of this automatic correction can be based on a proportional-integral control algorithm.

[0036] The controller 800 uses persistent deviations, such as actual temperatures consistently being 2 degrees Celsius lower than theoretical temperatures, as input to the integral term. The integrator accumulates this deviation over time, forming an integral cumulative value. When the controller 800 executes the S3 calculation next time, this integral cumulative value will be used as a correction coefficient or correction offset and added to the output of the S3 conversion model, i.e., the power correction waveform. For example, persistent negative deviations, such as lower temperatures, will cause the integral cumulative value to increase, thereby systematically increasing the output amplitude of the entire power correction waveform until the persistent deviation is eliminated and the integral cumulative value stops changing. This method ensures that the control model can learn autonomously and compensate for unmodeled factors such as heat loss.

[0037] In this way, the control method can continuously adjust its internal model during use to make it closer to the actual physical process, thereby improving the stability of process control across the entire speed range.

[0038] The dynamic overflow coating head 400 includes a coating chamber 410 and a variable frequency peristaltic pump 420. Non-contact air seal devices are provided at both ends of the coating chamber 410.

[0039] In the execution of the method, the dynamic overflow coating head 400, as a key execution component, has a clearly defined structure. The dynamic overflow coating head 400 includes a coating chamber 410 and a variable frequency peristaltic pump 420. Their functional relationship is as follows: the variable frequency peristaltic pump 420, such as a Watson-Marlow 530 series industrial peristaltic pump, serves as the power mechanism, responsible for precisely pumping the coating liquid into the coating chamber 410 according to the instructions of the controller 800; the coating chamber 410 is the space through which the steel wire passes and fully contacts the coating liquid. To ensure that the coating liquid does not leak from both ends of the chamber when the steel wire passes through at high speed, non-contact air-sealing devices are installed at both ends of the coating chamber 410; these non-contact air-sealing devices form an air curtain by blowing in high-pressure airflow, preventing liquid overflow at the inlet and outlet of the steel wire. This structural combination allows the controller 800 to precisely execute the reverse adjustment command in step S3 by adjusting the rotational speed, i.e., the pumping flow rate, of the variable frequency peristaltic pump 420.

[0040] The interior of the furnace body 510 of the multi-zone infrared drying oven 500 is divided into ten independent heating zones 520 along the direction of the steel wire travel.

[0041] To achieve precise transmission of the power correction waveform in step S3, the internal structure of the multi-zone infrared drying oven 500 is further defined. The interior of the oven body 510 of the multi-zone infrared drying oven 500 is divided into ten independent heating zones 520 along the direction of the steel wire travel. Each independent heating zone 520 contains its own infrared heating unit, such as multiple high-power infrared lamps, and its heating power can be independently adjusted by the controller 800. The purpose of dividing the oven into ten independent heating zones 520 is to provide the controller 800 with high-resolution heat control capabilities. This allows the controller 800 to simultaneously apply different heating powers to different segments along the steel wire path when transmitting the power correction waveform, allowing the heat output to form a precisely controllable waveform in both space and time. This waveform matches the actual position and heat demand of the steel wire micro-element under the dynamic correction velocity model, which is the physical basis for achieving dynamic drying control.

[0042] The main speed encoder 710 and the outlet speed encoder 720 are high-resolution photoelectric encoders; the outlet temperature measuring instrument 730 is a non-contact pyrometer 740.

[0043] To ensure the accuracy of the data acquired by the controller 800 meets the calculation requirements, the types of key sensors are specified. Both the main speed encoder 710 and the outlet speed encoder 720 are high-resolution photoelectric encoders, such as the Heidenhain ROD400 series. High-resolution photoelectric encoders are chosen because calculating the instantaneous total elastic elongation in step S3 requires relying on the very subtle difference between the inlet and outlet reference speeds, and ordinary encoders cannot provide sufficiently accurate data. The outlet temperature sensor 730 is a non-contact pyrometer 740, such as a Raytek MI3 series infrared thermometer. The non-contact pyrometer 740 is chosen because the steel wire is still moving at high speed and at a high temperature at the outlet, making contact measurement impossible. The non-contact pyrometer 740 can read the surface temperature of the steel wire in real time through infrared radiation, providing accurate actual outlet temperature data for comparison and correction in step S4.

[0044] Example 2 Please see Figure 1-4 A multi-stage continuous processing steel wire surface coating device for high-speed railway sleepers, comprising: Dynamic overflow coating head 400; The multi-zone infrared drying oven 500 is located on the outlet side of the dynamic overflow coating head 400 along the steel wire travel path. The multi-zone infrared drying oven 500 includes multiple independent heating zones 520. The main speed encoder 710 is located on the inlet side of the dynamic overflow coating head 400; An exit speed encoder 720 is installed on the exit side of the multi-zone infrared drying oven 500; The outlet temperature measuring instrument 730 is installed on the outlet side of the multi-zone infrared drying oven 500; The controller 800 is electrically connected to the dynamic overflow coating head 400, the multi-zone infrared drying oven 500, the main speed encoder 710, the outlet speed encoder 720, and the outlet temperature measuring instrument 730.

[0045] The present invention also provides an apparatus for implementing the above method. The apparatus includes a dynamic overflow coating head 400 and a multi-zone infrared drying oven 500, wherein the multi-zone infrared drying oven 500 is arranged along the steel wire travel path on the outlet side of the dynamic overflow coating head 400. This arrangement constitutes the core coating and drying process zone. The multi-zone infrared drying oven 500 itself includes multiple independent heating zones 520. The apparatus also includes sensors: a main speed encoder 710 is arranged on the inlet side of the dynamic overflow coating head 400 to measure the reference state of the steel wire entering the process zone; an outlet speed encoder 720 and an outlet temperature meter 730 are jointly arranged on the outlet side of the multi-zone infrared drying oven 500 to measure the final state of the steel wire after it leaves the process zone. The core of the device is the controller 800, such as an industrial PC or a high-end PLC. The controller 800 is electrically connected to the dynamic overflow coating head 400, the multi-zone infrared drying oven 500, the main speed encoder 710, the outlet speed encoder 720, and the outlet temperature sensor 730. This connection allows the controller 800 to obtain real-time steel wire status data from the main speed encoder 710, the outlet speed encoder 720, and the outlet temperature sensor 730, and then execute the built-in algorithm to send flow adjustment commands to the dynamic overflow coating head 400 and power correction commands to the multi-zone infrared drying oven 500, thus realizing a complete closed-loop system of status perception and dynamic control.

[0046] The dynamic overflow coating head 400 includes a variable frequency peristaltic pump 420 and a coating chamber 410. The coating chamber 410 is used to contain the coating liquid, and the variable frequency peristaltic pump 420 is used to pump the coating liquid into the coating chamber 410.

[0047] In one specific embodiment of the device, the structure of the dynamic overflow coating head 400 is described. The dynamic overflow coating head 400 includes a variable frequency peristaltic pump 420 and a coating chamber 410. The coating chamber 410 is the direct site for coating, functioning to contain the coating liquid and allow a steel wire to pass through it. The variable frequency peristaltic pump 420 is the power source for the coating liquid, functioning to pump the coating liquid into the coating chamber 410. The variable frequency peristaltic pump 420, for example as a precision fluid delivery device, receives control signals from the controller 800, such as a 4-20mA analog signal or Profinet communication commands, to precisely adjust its rotational speed, thereby achieving dynamic regulation of the flow rate pumped into the coating chamber 410. This structure enables the controller 800 to physically perform reverse regulation of the pumped flow rate.

[0048] The controller 800 is also used to establish a wire micro-element queue, which is used to logically divide continuously moving wires into virtual wire segments with independent process state data.

[0049] The internal data processing mechanism of the controller 800 is further explained within the device's controller functions. The controller 800 is also used to establish a wire micro-element queue; this queue is not a physical entity, but a data structure existing in the controller 800's memory. The purpose of establishing this queue is because the wire travels continuously without physical boundaries. The wire micro-element queue is used to logically divide the continuously traveling wire into virtual wire segments with independent process state data. Through this division, the controller 800 can create an independent data record for each virtual wire segment, for example, representing a 5-centimeter-long wire, to store state information such as the theoretical coating adhesion amount, theoretical cumulative heat absorption, and calculated position of that segment. This logical division and tracking is the computational basis for the controller 800 to apply different controls to the wire at different positions and times, such as power waveform transmission in S3 and state comparison in S4.

[0050] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A multi-stage continuous processing method for coating the surface of steel wire for high-speed railway sleepers, characterized in that, include: S1. A controller (800), a dynamic overflow coating head (400), a multi-zone infrared drying oven (500), a main speed encoder (710), an outlet speed encoder (720), and an outlet temperature measuring instrument (730) are set up, wherein the main speed encoder (710) is located on the inlet side, the dynamic overflow coating head (400) and the multi-zone infrared drying oven (500) are set up in sequence, and the outlet speed encoder (720) and the outlet temperature measuring instrument (730) are located on the outlet side; S2. The controller (800) reads the inlet reference speed of the main speed encoder (710) to establish a steel wire micro-element queue and tracks the queue to record the theoretical coating adhesion amount and theoretical cumulative heat absorption. The theoretical coating adhesion amount represents the total amount of coating material that a unit length of steel wire should obtain under the current process conditions, and serves as the reference target value for reverse adjustment of the pumping flow rate of the coating head. The theoretical cumulative heat absorption represents the total energy absorbed by the steel wire micro-element in all independent heating zones (520) from entering the drying oven to the outlet, and serves as the basis for calculating the theoretical outlet temperature. S3. When the controller (800) detects the change in the inlet reference speed, it reverses the pumping flow rate of the dynamic overflow coating head (400), and calculates the instantaneous total elastic elongation based on the speed difference between the inlet reference speed and the outlet drawing speed, and calculates the power correction waveform so that the power correction waveform is transmitted along the multiple independent heating zones (520) of the multi-zone infrared drying oven (500). S4. When the steel wire element reaches the outlet temperature measuring instrument (730), the controller (800) reads the actual outlet temperature, compares the actual and theoretical outlet temperatures, and corrects the conversion model of S3 according to the deviation.

2. The method for multi-stage continuous processing of steel wire surface coating for high-speed railway sleepers according to claim 1, characterized in that, In step S3: the controller (800) calculates a dynamic correction speed model based on the inlet reference speed and the instantaneous total elastic elongation, and the transmission speed of the power correction waveform in the independent heating zone (520) matches the dynamic correction speed model.

3. The multi-stage continuous processing method for coating the surface of steel wire for high-speed railway sleepers according to claim 2, characterized in that, In step S2: the theoretical coating adhesion amount is calculated based on the pump flow rate and the calculated residence time of the steel wire micro-element in the dynamic overflow coating head (400); The theoretical cumulative heat absorption is calculated and superimposed based on the heating power and the calculated residence time of the steel wire micro-element in the independent heating zone (520).

4. The multi-stage continuous processing method for coating the surface of steel wire for high-speed railway sleepers according to claim 3, characterized in that, In step S4: the deviation is the continuous deviation between the actual outlet temperature and the theoretical outlet temperature, and the controller (800) automatically corrects the conversion model used in S3 to calculate the power correction waveform.

5. The multi-stage continuous processing method for coating the surface of steel wire for high-speed railway sleepers according to claim 3, characterized in that, The dynamic overflow coating head (400) includes a coating chamber (410) and a variable frequency peristaltic pump (420), and non-contact air seal devices are provided at both ends of the coating chamber (410).

6. The multi-stage continuous processing method for coating the surface of steel wire for high-speed railway sleepers according to claim 3, characterized in that, The interior of the furnace body (510) of the multi-zone infrared drying oven (500) is divided into ten independent heating zones (520) along the direction of the steel wire travel.

7. The multi-stage continuous processing method for coating the surface of steel wire for high-speed railway sleepers according to claim 3, characterized in that, The main speed encoder (710) and the outlet speed encoder (720) are high-resolution photoelectric encoders; the outlet temperature measuring instrument (730) is a non-contact pyrometer (740).

8. A multi-stage continuous processing steel wire surface coating device for high-speed railway sleepers, applied to the multi-stage continuous processing steel wire surface coating method for high-speed railway sleepers as described in any one of claims 1 to 7, characterized in that, include: Dynamic overflow coating head (400); A multi-zone infrared drying oven (500) is disposed along the steel wire travel path on the outlet side of the dynamic overflow coating head (400), and the multi-zone infrared drying oven (500) includes multiple independent heating zones (520). A main speed encoder (710) is disposed on the inlet side of the dynamic overflow coating head (400); An exit speed encoder (720) is installed on the exit side of the multi-zone infrared drying oven (500); An outlet temperature measuring instrument (730) is installed on the outlet side of the multi-zone infrared drying oven (500); The controller (800) is electrically connected to the dynamic overflow coating head (400), the multi-zone infrared drying oven (500), the main speed encoder (710), the outlet speed encoder (720), and the outlet temperature measuring instrument (730).

9. A multi-stage continuous processing steel wire surface coating device for high-speed railway sleepers according to claim 8, characterized in that, The dynamic overflow coating head (400) includes a variable frequency peristaltic pump (420) and a coating chamber (410), the coating chamber (410) being used to contain coating liquid, and the variable frequency peristaltic pump (420) being used to pump coating liquid into the coating chamber (410).

10. A multi-stage continuous processing steel wire surface coating device for high-speed railway sleepers according to claim 9, characterized in that, The controller (800) is also used to establish a wire micro-element queue, which is used to logically divide continuously moving wires into virtual wire segments with independent process state data.

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