Powder spraying process monitoring method and system for automobile hub decorating part

Abstract

The invention discloses a powder spraying process monitoring method and system for an automobile hub decorating part, and relates to the technical field related to powder spraying monitoring, and the method comprises the steps: obtaining the geometric structure and coating information of a target decorating part, carrying out the planning of a powder spraying process period, carrying out the positioning of a monitoring point, and determining a powder spraying monitoring sequence; planning a monitoring mode and a monitoring element map according to a powder spraying scene of a target ornament, constructing a monitoring upper device, deploying the monitoring upper device in a powder spraying monitoring central controller in an embedded manner, and writing a powder spraying monitoring sequence into a first register built in the powder spraying monitoring central controller; and the powder electrostatic spraying equipment is braked along with the powder spraying process period, and polling monitoring control of directional monitoring verification based on the risk points in the period is executed. The technical problems that in the prior art, powder spraying technology monitoring is poor in real-time performance, risk point recognition is not accurate, and the coating quality of the ornament with the complex structure is difficult to control are solved, and the technical effects of full-process automatic monitoring, dynamic risk point directional control and improvement of coating uniformity and yield are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of powder spraying monitoring, and particularly relates to a powder spraying process monitoring method and system for automobile hub decoration parts. BACKGROUND

[0002] As an important part of the appearance of a vehicle, the quality of the surface coating of a hub decoration part directly affects the visual effect and durability of the vehicle. Powder electrostatic spraying technology has become the mainstream process for surface treatment of hub decoration parts due to its advantages such as environmental protection, high efficiency, and strong coating adhesion. However, in actual production, the quality of the powder spraying process is affected by various factors such as spraying parameters, powder material properties, and workpiece geometry. If not properly controlled, it can easily lead to defects such as uneven coating thickness, orange peel, and sagging, affecting product yield and performance. Traditional powder spraying process monitoring cannot achieve real-time monitoring throughout the process, and lacks targeted monitoring strategies for complex structure decoration parts. In particular, in single-layer powder spraying or composite powder spraying (such as multi-layer superimposed spraying) processes, the spraying parameters and curing conditions of different coatings may differ, further increasing the difficulty of process control. In addition, existing monitoring lacks dynamic identification and targeted detection capabilities for risk points, resulting in delayed problem discovery, increased rework costs, and production delay risks.

[0003] Therefore, in the related art, there are technical problems of poor real-time powder spraying process monitoring, inaccurate risk point identification, and difficulty in controlling the quality of the coating of complex structure decoration parts. SUMMARY

[0004] The present application provides a powder spraying process monitoring method and system for automobile hub decoration parts, which solves the technical problems of poor real-time powder spraying process monitoring, inaccurate risk point identification, and difficulty in controlling the quality of the coating of complex structure decoration parts in the prior art, and achieves the technical effects of full-process automation monitoring, dynamic risk point directional control, and improved coating uniformity and yield.

[0005] The present application provides a powder spraying process monitoring method for automobile hub decoration parts, which comprises: acquiring the geometry and coating information of a target decoration part, planning and positioning monitoring points for a powder spraying process cycle, and determining a powder spraying monitoring sequence, wherein the powder spraying mode throughout the cycle is single-layer powder spraying or composite powder spraying; planning a monitoring mode and a monitoring element map based on the powder spraying scene of the target decoration part, constructing a monitoring upper device, and embedding the monitoring upper device in a powder spraying monitoring central control unit; writing the powder spraying monitoring sequence into a first register built in the powder spraying monitoring central control unit; braking a powder electrostatic spraying device during the powder spraying process cycle, and performing polling monitoring control based on risk point directional monitoring and detection in the cycle by combining the first register and the monitoring upper device.

[0006] In a possible implementation, the powder spraying process monitoring method for the automobile wheel hub decoration part further performs the following processing: for the powder spraying process cycle, node-by-node judgment based on spraying precision and spraying stability is performed to locate risk points, wherein the risk points are error potential process nodes, and each risk point is identified with a risk guide; and the risk points are integrated as a powder spraying monitoring sequence based on the periodic timing of the powder spraying process cycle.

[0007] In a possible implementation, the powder spraying process monitoring method for the automobile wheel hub decoration part further performs the following processing: a first type of monitoring planning is performed based on spray gun parameters and powder cloud movement, wherein the first type of monitoring planning includes a monitoring mode and a monitoring element atlas; a second type of monitoring planning is performed based on the spatial alignment of the spray gun and the flexible auxiliary part; and a third type of monitoring planning is performed based on a sprayed layer state, wherein the sprayed layer state is before or after solidification; and the first type of monitoring planning, the second type of monitoring planning, and the third type of monitoring planning are fused to construct a monitoring upper device.

[0008] In a possible implementation, the powder spraying process monitoring method for the automobile wheel hub decoration part further performs the following processing: monitoring modes are aggregated and trigger boundary conditions are set as a first monitoring trigger layer; monitoring element atlases are aggregated and verification boundary conditions are set as a second verification judgment layer; and the first monitoring trigger layer and the second verification judgment layer are mapped to generate the monitoring upper device based on hierarchical pruning under multiple process states as a training target.

[0009] In a possible implementation, the powder spraying process monitoring method for the automobile wheel hub decoration part further performs the following processing: the powder spraying monitoring sequence is written into a first register, wherein the first register is a built-in plug-in of a powder spraying monitoring central control; and the monitoring upper device is embedded and deployed in the powder spraying monitoring central control and communicates with a powder electrostatic spraying device and a monitoring array of a target decoration part powder spraying scene, wherein the monitoring array includes a monitoring component assembled with the powder electrostatic spraying device and an external monitoring component.

[0010] In a possible implementation, the powder spraying process monitoring method for the automobile wheel hub decoration part further performs the following processing: powder spraying control of the powder electrostatic spraying device is driven according to the powder spraying process cycle; the first register generates a polling signal according to the periodic timing of the risk points and assists the monitoring upper device to perform directional monitoring control of the monitoring mode according to the risk guide of the risk points and directional verification control based on the monitoring elements, along with the braking process of the powder electrostatic spraying device.

[0011] In a possible implementation, the method for monitoring the powder coating process of automotive wheel hub trim parts further includes the following steps: when a first risk point is reached, the first register generates a first monitoring signal based on a first risk guide; the monitoring host receives the first monitoring signal, and in the first monitoring trigger layer, performs condition matching analysis between the first risk guide and the trigger boundary conditions, prunes non-matching items in the monitoring mode, and determines a first monitoring instruction; according to the first monitoring instruction, the directional monitoring drive of the monitoring array is executed to determine the first monitoring data.

[0012] In a possible implementation, the method for monitoring the powder coating process of automotive wheel hub trim parts further includes the following processing: in the second verification judgment layer, by performing a matching analysis between the first risk guidance and the verification boundary conditions, non-matching items are pruned from the monitoring element map to determine the second verification sub-map; the first monitoring data is returned, and with the second verification sub-map as the monitoring range, anomaly judgment based on map elements is performed to generate the first monitoring result.

[0013] In a possible implementation, the method for monitoring the powder coating process of automotive wheel hub trim parts further includes the following steps: generating a first powder coating state bias command based on the first monitoring result; the powder coating monitoring control center issues the first powder coating state bias command to perform powder coating control alarm and feedback regulation of powder coating conditions.

[0014] This application also provides a powder coating process monitoring system for automotive wheel hub trim parts. The system includes: a powder coating monitoring sequence determination module, used to acquire the geometric structure and coating information of the target trim part, plan the powder coating process cycle and locate monitoring points, and determine the powder coating monitoring sequence, wherein the powder coating method for the entire cycle is single-layer powder coating or composite powder coating; a monitoring host device construction module, used to plan the monitoring mode and monitoring element map based on the powder coating scenario of the target trim part, construct a monitoring host device, which is embedded in the powder coating monitoring central control, and writes the powder coating monitoring sequence into the first register built into the powder coating monitoring central control; and a polling monitoring and control module, used to brake the powder electrostatic spraying equipment according to the powder coating process cycle, and, in conjunction with the first register and the monitoring host device, execute polling monitoring and control based on risk point-oriented monitoring and verification within the cycle.

[0015] This application proposes a method and system for monitoring the powder coating process of automotive wheel hub trim parts. The method acquires the geometric structure and coating information of the target trim part, plans the powder coating process cycle and locates monitoring points, and determines the powder coating monitoring sequence. Based on the powder coating scenario of the target trim part, the method plans the monitoring mode and monitoring element map, constructs a monitoring host computer, and embeds it in the powder coating monitoring central control unit. The powder coating monitoring sequence is written into the first register built into the powder coating monitoring central control unit. During the powder coating process cycle, the electrostatic powder coating equipment is braked, and polling monitoring and control based on risk point-oriented monitoring and verification is performed within the cycle. This method solves the technical problems of poor real-time performance of powder coating process monitoring, inaccurate risk point identification, and difficulty in controlling the coating quality of complex structural trim parts in existing technologies. It achieves the technical effects of fully automated monitoring, dynamic risk point-oriented control, and improved coating uniformity and yield. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings of the embodiments of this disclosure will be briefly described below. Flowcharts are used in this application to illustrate the operations performed by the system according to the embodiments of this application. It should be understood that the preceding or following operations are not necessarily performed precisely in sequence. Instead, various steps can be processed in reverse order or simultaneously as needed. Furthermore, other operations can be added to these processes, or one or more steps can be removed from these processes.

[0017] Figure 1 This is a schematic flowchart of a powder coating process monitoring method for automotive wheel hub decorative parts, provided as an embodiment of this application.

[0018] Figure 2 This is a schematic diagram of a powder coating process monitoring system for automotive wheel hub trim parts, provided as an embodiment of this application.

[0019] Figure labeling: Module 10 for determining the powder spraying monitoring sequence, Module 20 for constructing the monitoring host, and Module 30 for polling monitoring and control. Detailed Implementation

[0020] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and in order to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application.

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description of this application will be provided in conjunction with the accompanying drawings. The described embodiments should not be considered as limitations on this application. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] In the following description, references to "some embodiments" describe a subset of all possible embodiments. However, it is understood that "some embodiments" can be the same or different subsets of all possible embodiments and can be combined with each other without conflict. The terms "first" and "second" are used merely to distinguish similar objects and do not represent a specific ordering of objects. The terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or modules not explicitly listed or inherent to these processes, methods, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only.

[0023] This application provides a method for monitoring the powder coating process of automotive wheel hub trim parts, such as... Figure 1 As shown, the method includes: Step S100: Obtain the geometric structure and coating information of the target trim, plan the powder coating process cycle and locate the monitoring points, and determine the powder coating monitoring sequence. The powder coating method for the entire cycle is either single-layer powder coating or composite powder coating.

[0024] Preferably, a high-precision 3D scanner (such as LiDAR or optical scanning equipment) is used to perform an all-round scan of the wheel hub trim to generate point cloud data. Combined with binocular vision or ToF camera, multi-angle image acquisition and 3D reconstruction are used to quickly obtain the surface morphology of the trim. Combined with edge detection algorithm, the high-precision spraying area is located, thereby obtaining the geometric structure of the target trim, that is, the three-dimensional shape features of the wheel hub trim, such as surface curvature, hollow area, edge thickness, etc. Different structures affect the uniformity of powder coating coverage. For example, powder is easy to accumulate in the groove and thin spraying is easy to occur at the corners. Based on production orders or process specifications, the coating type is retrieved from the enterprise's MES / ERP system. Simultaneously, an infrared spectrometer / XRF analyzer is used to analyze the composition of the incoming powder to obtain coating information for the target part, including coating type (single-layer powder coating or composite powder coating), material characteristics (such as powder particle size and curing temperature), and expected thickness. Single-layer powder coating involves spraying only one type of powder, such as solid-color epoxy resin powder; composite powder coating refers to multi-layer overlapping, such as base powder + transparent topcoat powder, and the differences in interlayer bonding strength and curing parameters need to be considered.

[0025] Preferably, the powder coating process cycle is planned by dividing the powder coating process into time-series nodes, such as pretreatment → spraying → curing → cooling, and setting parameters for different powder coating methods, such as spray gun movement speed, voltage, and powder flow rate. Then, monitoring points are located, that is, based on the geometric structure and coating requirements, error-prone risk points are identified, such as insufficient spraying accuracy and unstable powder cloud movement. For single-layer powder coating, the focus is on edge and corner coverage and powder cloud uniformity. For composite powder coating, additional monitoring of interlayer curing status is required; for example, insufficient curing of the first layer will lead to poor adhesion of the second layer. Then, the risk monitoring points are arranged according to the process sequence to form a dynamic detection instruction chain, i.e., the powder coating monitoring sequence. For example, for composite powder coating, the distance between the spray gun and the trim is monitored during the spraying stage to prevent powder scattering; during interlayer transition, infrared thermography is used to detect the curing degree of the first layer; and finally, a laser thickness gauge is used to check the overall coating thickness. By accurately acquiring geometric and coating information, a powder coating monitoring sequence is dynamically generated to achieve precise and controllable spraying of blind spots in complex structures.

[0026] Furthermore, step S100 also includes step S110, which involves determining the spraying accuracy and spraying stability for each node in the powder coating process cycle and locating risk points, wherein the risk points are potential error process nodes and each risk point is marked with a risk guide; step S120, which integrates the risk points based on the periodic time sequence of the powder coating process cycle as a powder coating monitoring sequence.

[0027] Preferably, the powder coating process cycle is divided into several key nodes, such as cleaning, degreasing, and phosphating in the pretreatment stage; electrostatic powder coating in the spraying stage; infrared / UV curing in the curing stage; and final inspection after cooling in the cooling and quality inspection stage. At each node, the coating thickness, coverage uniformity, and other spraying accuracy and stability, such as the consistency of the spray gun movement trajectory and the density of powder clouds, need to be judged in real time. Deviations are detected and risk points are located by using laser thickness gauges, infrared thermal imagers, etc., that is, process nodes with potential errors. These are the links where equipment, materials, or environmental factors can easily lead to coating quality deviations. For example, in the spraying stage, uneven electrostatic adsorption in curved areas can lead to powder... During the final deposition and curing stage, temperature fluctuations lead to insufficient interlayer adhesion. Each risk point is labeled with a risk guide, including specific failure modes and directions of impact. For example, if the spray gun is too far from the curved surface, the coating thickness will be insufficient, resulting in exposed substrate at the edges; if the curing temperature is too low, the interlayer adhesion will be poor, leading to coating peeling. Finally, the risk points are integrated based on the periodic time sequence of the powder coating process cycle. That is, the risk points are sorted according to the process time axis to form a dynamic monitoring instruction chain, which serves as the powder coating monitoring sequence. If a risk point (such as spray gun blockage) triggers an anomaly in real time, the sequence will automatically insert an emergency detection node. At the same time, the monitoring frequency of high-risk nodes such as interlayer curing of composite powder coating will be increased.

[0028] Step S200: Based on the powder spraying scene of the target ornament, plan the monitoring mode and monitoring element map, build a monitoring host, embed it in the powder spraying monitoring central control, and write the powder spraying monitoring sequence into the first register built into the powder spraying monitoring central control.

[0029] Preferably, the powder coating scenario for the target trim refers to the specific working environment of the wheel trim during the coating process, including the trim type, such as high-gloss wheel, matte wheel, and sports wheel with hollow structure; the coating method, single-layer powder coating or composite powder coating; the production line configuration, such as automated coating robots, curing oven type (infrared / UV), and ambient temperature and humidity; and different monitoring modes and monitoring element maps are customized based on the powder coating scenario. Specifically, the monitoring mode refers to the data collection and analysis strategy set for different powder coating stages, which is usually divided into three types: Class I monitoring plan, Class II monitoring plan, and Class III monitoring plan. Among them, Class I monitoring plan monitors the spray gun parameters - powder cloud movement; Class II monitoring plan monitors the spatial alignment of the spray gun and flexible auxiliary parts; and Class III monitoring plan monitors the spray layer status. The monitoring element map is a key parameter relationship network used for structured storage and analysis of monitoring data. For example, the related parameters of powder cloud density include spray gun voltage and atomization pressure. An alarm is triggered if the density fluctuation is >15%. Then, an embedded intelligent analysis module is constructed as a monitoring host to receive real-time data from laser thickness gauges and infrared cameras. Based on the monitoring element map, it compares the actual data with the standard range and triggers control commands when anomalies are detected, such as adjusting the spray gun speed or curing temperature. The monitoring host is embedded in the powder coating monitoring control center, meaning it runs directly on the industrial PLC or industrial control computer of the powder coating equipment, interacting with hardware such as the spraying robot and curing oven in real time to avoid communication delays. Finally, the powder coating monitoring sequence is written into the first register built into the powder coating monitoring control center. The first register is a high-speed storage unit built into the powder coating control center to store time-sequential monitoring commands, such as "detect the powder cloud density 5 seconds after the start of spraying," to ensure that the monitoring commands are triggered accurately according to the process cycle, thereby achieving precise and automated control of the powder coating process and significantly improving the stability of coating quality.

[0030] Furthermore, step S200 also includes step S210, which performs a first-class monitoring plan based on the spray gun parameters - powder cloud movement, wherein the first-class monitoring plan includes a monitoring mode and a monitoring element map; step S220, which performs a second-class monitoring plan based on the spatial alignment of the spray gun and the flexible auxiliary component; step S230, which performs a third-class monitoring plan based on the spray layer state, wherein the spray layer state is before or after curing; and step S240, which integrates the first-class monitoring plan, the second-class monitoring plan and the third-class monitoring plan to construct a monitoring host device.

[0031] Preferably, a first-class monitoring plan is implemented based on spray gun parameters and powder cloud movement. This includes monitoring modes and monitoring element maps. Specifically, a high-speed camera collects spray gun operating parameters such as voltage and powder flow rate. A convolutional neural network is used to process the cloud images to identify agglomeration / void phenomena, quantify cloud uniformity, and an adaptive PID control algorithm is used to adjust spray gun parameters in real time to ensure the stability and controllability of the physical process of powder coating. A second-class monitoring plan is implemented based on the spatial alignment of the spray gun and flexible auxiliary components. This involves combining laser tracker and encoder data for six-dimensional pose synchronization detection and predicting the spraying path based on the movement trajectory of the component to ensure the integrity of the coating coverage on complex curved surfaces. A third-class monitoring plan is implemented based on the spray layer state, whether before or after curing. Online detection before curing is performed using a laser triangulation thickness gauge and structured light 3D scanning, including wet film thickness / leveling analysis. Final inspection after curing is performed using an automatic cross-cutting instrument and image analysis to ensure that the final coating performance meets the standards. Finally, the Class I, Class II, and Class III monitoring plans are integrated to construct an embedded monitoring host, enabling multi-dimensional analysis of the powder spraying process status.

[0032] Furthermore, step S200 also includes step S250, aggregating monitoring modes and setting trigger boundary conditions as the first monitoring trigger layer; step S260, aggregating monitoring element maps and setting verification boundary conditions as the second verification judgment layer; step S270, mapping the first monitoring trigger layer and the second verification judgment layer, and generating the monitoring host device with hierarchical pruning based on multi-process states as the training target.

[0033] Preferably, all monitoring modes are aggregated, such as spray gun parameters, spatial alignment, and spray layer status. Dynamic trigger boundary conditions are set, such as triggering a level one alarm when the spray gun voltage > 85kV, thus constructing a first monitoring trigger layer for real-time scanning of process status and rapid identification of abnormal signs. Monitoring element maps are aggregated, such as voltage-flow-temperature correlation models, and multi-dimensional verification boundaries are set. For example, when the voltage exceeds the limit and the cloud density is < 70%, it is determined to be a powder supply system failure. A fault tree is constructed based on the knowledge graph, establishing a second verification and judgment layer for in-depth analysis of the root causes of abnormalities and formulation of precise control strategies. The first monitoring trigger layer and the second verification and judgment layer are mapped, i.e., through process status coding. For example, binary status words can be used to accurately associate trigger layer signals with corresponding analysis modules in the judgment layer. Then, hierarchical pruning based on multiple process states is used as the training target. Specifically, real-time process parameters such as voltage, distance, and temperature are used as inputs. A random forest model is used to prune non-critical paths. For example, when the temperature is normal, the relevant branch analysis is ignored. After optimization, a decision tree model is output to generate a monitoring host. When trigger layer alarms (powder flow rate drops by 30%) and judgment layer correlation analysis (gas pressure is normal but voltage fluctuates) are detected at the same time, the gas pressure fault branch is automatically pruned to quickly locate the root cause of the powder supply pipeline blockage, thereby improving the fault handling efficiency of the powder spraying process.

[0034] Furthermore, step S200 also includes step S280, writing the powder spraying monitoring sequence into the first register, wherein the first register is a built-in plug-in of the powder spraying monitoring control center; step S290, embedding the monitoring host device into the powder spraying monitoring control center, and establishing communication interaction with the powder electrostatic spraying equipment and monitoring array of the target trim powder spraying scene, wherein the monitoring array includes the monitoring components assembled in the powder electrostatic spraying equipment and external monitoring components.

[0035] Preferably, precise and real-time monitoring of the powder coating process is achieved through register storage of monitoring sequences and collaborative control with an embedded host computer. Specifically, the powder coating monitoring sequence is written into the first register, which is a built-in plug-in of the powder coating monitoring control center. It serves as a high-speed storage unit for the powder coating monitoring control center (such as an industrial PLC or a dedicated industrial control computer) to store time-sequential monitoring instructions, such as detecting the powder cloud density 3 seconds after the start of spraying and measuring the spray gun distance 5 seconds after the start of spraying. This ensures that the monitoring instructions are triggered strictly according to the process cycle, avoids delays caused by manual intervention, and supports dynamic updates, such as inserting interlayer curing detection nodes in composite powder coating. The monitoring host is embedded in the powder coating monitoring control center, operating at the same level as powder electrostatic spraying equipment such as spraying robots and curing ovens. This eliminates the communication delays of traditional PC architectures, enabling real-time reading of monitoring sequences from registers, driving sensors to perform detection, and analyzing data to provide feedback on control commands, such as automatically adjusting spray gun voltage or conveyor belt speed. Simultaneously, it establishes communication with the monitoring array, which includes monitoring components integrated into the powder electrostatic spraying equipment and external monitoring components. Monitoring components refer to sensors integrated into the spraying equipment, such as powder flow meters and electrostatic detectors; external components refer to flexibly deployed detection devices, such as infrared thermal imagers and laser thickness gauges.

[0036] In step S300, the powder electrostatic spraying equipment is braked according to the powder spraying process cycle, and polling monitoring and control based on risk point-oriented monitoring and verification is executed in conjunction with the first register and the monitoring host device within the cycle.

[0037] Preferably, precise quality management of the powder coating process is achieved through time-sequential braking control and intelligent polling monitoring. Specifically, the powder electrostatic spraying equipment is braked according to the powder coating process cycle. That is, at each node of the powder coating process, such as the start and stop of spraying and the interlayer transition stage, the central control system sends graded braking commands to the powder electrostatic spraying equipment. These include first-level braking to reduce the conveyor belt speed to improve detection accuracy, and second-level braking to suspend the movement of the spray gun for high-risk areas such as deep hole structures. Furthermore, the braking is strictly aligned with the powder coating monitoring sequence stored in the first register. For example, when the base powder coating is completed and the conveyor belt speed is reduced by 50%, infrared curing detection is initiated.

[0038] Preferably, the first register and the monitoring host are combined to perform polling monitoring and control based on risk point-oriented monitoring and verification within the execution cycle. Specifically, the first register releases monitoring commands according to a preset time sequence, and the monitoring host responds to the commands in real time, calling the corresponding laser thickness gauge / infrared thermal imager and other sensors to complete data acquisition and analysis, including risk point feature extraction and boundary condition determination. Then, a three-level polling mechanism is used for differentiated processing. For key point risks in the curved surface transition area, real-time adjustment and audible and visual alarms are set; for secondary point risks covered by planar areas, trend warnings are issued and logs are recorded; for background point risks in environmental temperature and humidity monitoring, periodic sampling is performed; when the host identifies a thickness deviation >15%, a compensation spraying subroutine is automatically inserted, and the powder spraying monitoring sequence in the first register is updated, realizing full-process automated monitoring, dynamic risk point-oriented control, and improved coating uniformity and yield in the complex decorative part spraying process.

[0039] Furthermore, step S300 also includes step S310, driving the powder spraying control of the electrostatic powder coating equipment according to the powder spraying process cycle; step S320, as the electrostatic powder coating equipment brakes, the first register generates monitoring signals by polling according to the periodic sequence of risk points, and assists the monitoring host in performing directional monitoring and control of the monitoring mode and directional verification and control based on monitoring elements according to the risk guidance of the risk points.

[0040] Preferably, by combining time-sequential powder spraying control with risk-oriented monitoring, precise closed-loop management of the wheel hub decorative parts spraying process can be achieved. Specifically, according to the powder spraying process cycle, the powder spraying control of the electrostatic powder spraying equipment is driven. That is, according to the process stage, such as base powder spraying, topcoat spraying, and curing, the parameters of the electrostatic powder spraying equipment are automatically switched. The servo motor is used to precisely control the trajectory of the spray gun, and short-term braking is triggered at risk points such as curved surface turning points, such as the spray gun pausing its movement and the powder flow rate dropping to the maintenance value, to create steady-state conditions for high-precision detection.

[0041] Preferably, the first register generates monitoring signals based on the periodic sequence of risk points. Specifically, during the braking interval of the powder electrostatic spraying equipment, detection is triggered according to the risk level. Curing temperature is forcibly checked every 0.5 seconds to identify high-risk points and interlayer transitions; coating thickness is sampled every 2 seconds to identify common risk points and planar spraying. Then, the risk-oriented auxiliary monitoring host performs targeted monitoring and control based on the risk points. This means that the monitoring mode is matched according to the risk type, such as accuracy or stability. For example, when there is a risk of uneven powder cloud formation, high-speed camera analysis is prioritized; when there is a risk of spray gun alignment deviation, a laser tracker is immediately invoked for verification. Simultaneously, targeted verification and control based on monitoring elements are performed. This involves comparing real-time data with monitoring element maps to determine if the process window is exceeded. When the wet film thickness exceeds the standard, related parameters, such as atomization pressure and electrostatic voltage, are automatically traced to pinpoint the root cause. This achieves fully automated monitoring throughout the process, dynamic targeted control of risk points, and improved coating uniformity and yield.

[0042] Furthermore, step S300 also includes step S330, whereby when the first risk point is reached, the first register generates a first monitoring signal based on the first risk guidance; step S340, whereby the monitoring host receives the first monitoring signal, and in the first monitoring trigger layer, performs condition matching analysis between the first risk guidance and the trigger boundary conditions, prunes non-matching items in the monitoring mode, and determines the first monitoring instruction; step S350, whereby, according to the first monitoring instruction, the directional monitoring drive of the monitoring array is executed, and the first monitoring data is determined.

[0043] Preferably, a three-level joint control response is used to accurately identify and handle powder spraying risk points. Specifically, when the powder spraying process reaches the preset first risk point, such as the interlayer transition node of composite powder spraying, the first register acts as a timing sentinel and immediately generates a structured monitoring signal, namely, a first monitoring signal based on the first risk, which includes risk type coding, associated process parameters, and the highest priority mark. The monitoring host receives the first monitoring signal and completes three-level processing at the first monitoring trigger layer, including performing condition matching analysis between the first risk guidance and the trigger boundary conditions, that is, comparing with the pre-stored trigger boundary condition library to confirm the validity of the risk and filter false alarm signals, such as instantaneous temperature fluctuations. Then, the monitoring mode is pruned for non-matching items, including using a decision tree model to quickly eliminate irrelevant monitoring items, retaining infrared thermal imaging monitoring and curing oven wind speed detection, and removing spray gun alignment checks, thereby generating a first monitoring command that specifies the activated sensors, such as online infrared spectrometers, sampling frequency, and data format requirements. Finally, the directional monitoring drive of the monitoring array is executed according to the first monitoring instruction. That is, after receiving the instruction, the monitoring array starts targeted detection, including scanning the risk area, adjusting the infrared detection wavelength to the optimal curing analysis band, and completing full data acquisition during the equipment braking window to obtain the first monitoring data, thereby improving the efficiency of risk handling in the powder coating process of automotive wheel hub trim parts and reducing unnecessary detection energy consumption.

[0044] Furthermore, step S350 further includes step S351, in the second verification judgment layer, by performing a matching analysis between the first risk guidance and the verification boundary conditions, non-matching items are pruned in the monitoring element map to determine the second verification sub-map; step S352, the first monitoring data is returned, and with the second verification sub-map as the monitoring range, anomaly judgment based on map elements is performed to generate the first monitoring result.

[0045] Preferably, a dual-layer verification system is used to accurately determine powder coating quality anomalies. Specifically, when the first monitoring data is transmitted back to the second verification and judgment layer, the monitoring host analyzes the first risk orientation against the verification boundary conditions in the second verification and judgment layer. It then prunes the monitoring element spectrum for non-matching items, extracting relevant parameters from the complete monitoring element spectrum, including retaining curing temperature gradient, hot air flow rate, and film thickness change rate, while removing irrelevant elements such as spray gun travel speed and powder particle size distribution. This determines the second verification sub-graph, containing only key monitoring parameters. Then, using the second verification sub-graph as the monitoring scope, anomaly judgment based on spectrum elements is performed. This involves multi-dimensional cross-validation within the narrowed analysis scope, including comparing real-time data with process standards and checking the logical relationships between parameters. A structured conclusion containing the anomaly level, root cause location, and remediation suggestions is output as the first monitoring result, categorized as warning, severe, or fatal. Through intelligent data dimensionality reduction and correlation analysis, rapid location and handling of complex quality problems are achieved.

[0046] Furthermore, step S350 also includes step S353, generating a first powder spraying state bias command based on the first monitoring result; step S354, the powder spraying monitoring control center issues the first powder spraying state bias command to perform powder spraying control alarm and feedback regulation of powder spraying conditions.

[0047] Preferably, after the monitoring host computer generates the first monitoring result, the powder spraying monitoring central control immediately generates the first powder spraying state bias instruction, which includes parameter adjustment amount, execution sequence and priority mark. For example, the moving speed of the spray gun in the edge area is reduced by 40% while the curing temperature of the area is increased by 15°C. The powder spraying monitoring central control is used to send the instruction to the powder electrostatic spraying equipment in real time through the industrial bus to execute the powder spraying control alarm and the feedback regulation of the powder spraying condition, that is, to trigger a three-level response, including automatic correction of the parameters executed by the equipment, such as adjusting the speed of the spray gun servo motor; the central control interface displays visual alarms to locate abnormal areas; and the production management system records deviation events. In this way, a fully automatic closed-loop control is completed from defect identification to process adjustment, thereby improving the coating uniformity and yield.

[0048] In the above text, refer to Figure 1 A method for monitoring the powder coating process of automotive wheel hub trim parts according to an embodiment of the present invention is described in detail. Next, reference will be made to... Figure 2 This invention describes a powder coating process monitoring system for automotive wheel hub trim parts according to an embodiment of the present invention.

[0049] According to an embodiment of the present invention, a powder coating process monitoring system for automotive wheel hub trim parts is provided to solve the technical problems existing in the prior art, such as poor real-time monitoring of the powder coating process, inaccurate identification of risk points, and difficulty in controlling the coating quality of complex structural trim parts. It achieves the technical effects of fully automated monitoring, dynamic targeted control of risk points, and improved coating uniformity and yield. Figure 2 As shown, a powder coating process monitoring system for automotive wheel hub trim parts includes: a powder coating monitoring sequence determination module 10, a monitoring host device construction module 20, and a polling monitoring and control module 30.

[0050] The powder coating monitoring sequence determination module 10 is used to acquire the geometric structure and coating information of the target part, plan the powder coating process cycle and locate monitoring points, and determine the powder coating monitoring sequence. The powder coating method for the entire cycle is single-layer powder coating or composite powder coating. The monitoring host device construction module 20 is used to plan the monitoring mode and monitoring element map based on the powder coating scene of the target part, construct the monitoring host device, and embed it in the powder coating monitoring central control. The powder coating monitoring sequence is written into the first register built into the powder coating monitoring central control. The polling monitoring and control module 30 is used to brake the powder electrostatic spraying equipment according to the powder coating process cycle, and, in conjunction with the first register and the monitoring host device, execute polling monitoring and control based on risk point-oriented monitoring and verification within the cycle.

[0051] The specific configuration of the powder coating monitoring sequence determination module 10 will be described in detail below. The powder coating monitoring sequence determination module 10 further includes: for the powder coating process cycle, performing node-by-node judgment based on coating accuracy and coating stability to locate risk points, wherein the risk points are potential error process nodes, and each risk point is marked with a risk guide; and integrating the risk points according to the periodic time sequence based on the powder coating process cycle to form a powder coating monitoring sequence.

[0052] The specific configuration of the monitoring host computer construction module 20 will be described in detail below. The monitoring host computer construction module 20 further includes: a first-type monitoring plan based on spray gun parameters – powder cloud movement, wherein the first-type monitoring plan includes monitoring modes and monitoring element maps; a second-type monitoring plan based on the spatial alignment of the spray gun and the flexible auxiliary component; a third-type monitoring plan based on the spray layer state, wherein the spray layer state is before or after curing; and the integration of the first-type, second-type, and third-type monitoring plans to construct the monitoring host computer.

[0053] The specific configuration of the monitoring host computer construction module 20 will be described in detail below. The monitoring host computer construction module 20 further includes: aggregating monitoring modes and setting trigger boundary conditions as a first monitoring trigger layer; aggregating monitoring element maps and setting verification boundary conditions as a second verification judgment layer; mapping the first monitoring trigger layer and the second verification judgment layer, and generating the monitoring host computer with hierarchical pruning based on multi-process states as the training target.

[0054] The specific configuration of the monitoring host computer module 20 will be described in detail below. The monitoring host computer module 20 further includes: writing the powder spraying monitoring sequence into a first register, wherein the first register is a built-in plug-in of the powder spraying monitoring central control unit; embedding the monitoring host computer in the powder spraying monitoring central control unit, and establishing communication interaction with the powder electrostatic spraying equipment and monitoring array of the target trim powder spraying scene, wherein the monitoring array includes monitoring components assembled in the powder electrostatic spraying equipment and external monitoring components.

[0055] The specific configuration of the polling monitoring and control module 30 will be described in detail below. The polling monitoring and control module 30 further includes: driving the powder spraying control of the electrostatic powder coating equipment according to the powder spraying process cycle; as the electrostatic powder coating equipment brakes, the first register generates monitoring signals by polling according to the periodic timing of risk points; based on the risk guidance of the risk points, it assists the monitoring host in performing directional monitoring and control of the monitoring mode, and directional verification and control based on monitoring elements.

[0056] The specific configuration of the polling monitoring and control module 30 will be described in detail below. The polling monitoring and control module 30 further includes: when a first risk point is reached, the first register generates a first monitoring signal based on a first risk orientation; the monitoring host receives the first monitoring signal, and in the first monitoring trigger layer, performs condition matching analysis between the first risk orientation and the trigger boundary conditions, prunes non-matching items in the monitoring mode, and determines a first monitoring instruction; according to the first monitoring instruction, it executes the directional monitoring drive of the monitoring array to determine the first monitoring data.

[0057] The specific configuration of the polling monitoring and control module 30 will be described in detail below. The polling monitoring and control module 30 further includes: in the second verification judgment layer, by performing a matching analysis between the first risk orientation and the verification boundary conditions, pruning non-matching items in the monitoring element map to determine a second verification sub-map; returning the first monitoring data, using the second verification sub-map as the monitoring range, performing anomaly judgment based on map elements, and generating a first monitoring result.

[0058] The specific configuration of the polling monitoring and control module 30 will be described in detail below. The polling monitoring and control module 30 further includes: generating a first powder spraying state bias command based on the first monitoring result; the powder spraying monitoring central control issuing the first powder spraying state bias command to execute powder spraying control alarms and feedback regulation of powder spraying conditions.

[0059] The powder coating process monitoring system for automotive wheel hub trim parts provided in this embodiment of the invention can execute the powder coating process monitoring method for automotive wheel hub trim parts provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects of the execution method.

[0060] Although this application makes various references to certain modules in the system according to the embodiments of this application, any number of different modules can be used and run on user terminals and / or servers. The various units and modules included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of each functional unit are only for easy distinction between each other and are not used to limit the scope of protection of this invention.

[0061] The specific embodiments described above do not constitute a limitation on the scope of protection of this application. Those skilled in the art should understand that various modifications, combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for monitoring the powder coating process of automotive wheel hub decorative parts, characterized in that, The method comprises: acquiring the geometry and coating information of the target ornament, planning and positioning the monitoring points of the powder spraying process cycle, and determining the powder spraying monitoring sequence, wherein the powder spraying mode of the whole cycle is single-layer powder spraying or composite powder spraying; planning the monitoring mode and monitoring element atlas based on the powder spraying scene of the target ornament, constructing the monitoring upper device, and embedding it in the powder spraying monitoring central control, and writing the powder spraying monitoring sequence into the first register built in the powder spraying monitoring central control; combined with the first register and the monitoring upper device, the polling monitoring control of the directional monitoring and detection in the cycle based on the risk points is executed.

2. The method of claim 1, wherein the method further comprises: determining a powdering process state of the automobile wheel hub trim based on the at least one of the first and second signals. The monitoring point positioning and the determination of the powder spraying monitoring sequence comprise: for the powder spraying process cycle, the spraying accuracy and spraying stability are judged node by node to locate the risk points, wherein the risk points are error potential process nodes, and each risk point is marked with a risk direction; based on the periodic timing of the powder spraying process cycle, the risk points are integrated as the powder spraying monitoring sequence.

3. The method of claim 1, wherein the powder spraying process of the automobile wheel hub trim is monitored by using a camera and a computer program. The planning of the monitoring mode and the monitoring element atlas and the construction of the monitoring upper device comprise: based on the gun parameter-powder cloud movement, a type of monitoring planning is carried out, wherein the type of monitoring planning includes the monitoring mode and the monitoring element atlas; based on the space alignment of the gun and the flexible auxiliary part, a type of monitoring planning is carried out; based on the spraying layer state, a type of monitoring planning is carried out, wherein the spraying layer state is before or after curing; the type of monitoring planning, the type of monitoring planning and the type of monitoring planning are fused to construct the monitoring upper device.

4. The method of claim 3, wherein the powder spraying process of the automobile wheel hub trim is monitored by using the camera. The monitoring mode is aggregated and the trigger boundary condition is set as the first monitoring trigger layer; the monitoring element atlas is aggregated and the detection boundary condition is set as the second detection judgment layer; the first monitoring trigger layer and the second detection judgment layer are mapped to generate the monitoring upper device based on the hierarchical pruning of the multi-process state as the training target.

5. The method of claim 1, wherein the method further comprises: determining a powdering process of the automobile wheel hub trim based on the at least one of the first and second images. The powder spraying monitoring sequence is written into the first register, wherein the first register is a built-in plug-in of the powder spraying monitoring central control; the monitoring upper device is embedded in the powder spraying monitoring central control and communicates with the powder electrostatic spraying equipment and the monitoring array of the target ornament powder spraying scene, wherein the monitoring array includes the monitoring components assembled by the powder electrostatic spraying equipment and the external monitoring components.

6. The method of claim 4, wherein the powder spraying process of the automobile wheel hub trim is monitored by using a camera and a computer program. combined with the first register and the monitoring upper device, the polling monitoring control of the directional monitoring and detection in the cycle based on the risk points is executed, comprising: according to the powder spraying process cycle, the powder spraying control of the powder electrostatic spraying equipment is driven; combined with the first register and the monitoring upper device, the polling monitoring control of the directional monitoring and detection in the cycle based on the risk points is executed, comprising:

7. A process monitoring method for a powder spraying of an automobile wheel cover according to claim 6, wherein according to the powder spraying process cycle, the powder spraying control of the powder electrostatic spraying equipment is driven; combined with the first register and the monitoring upper device, the polling monitoring control of the directional monitoring and detection in the cycle based on the risk points is executed, comprising: when the first risk point is reached, the first register generates the first monitoring signal based on the first risk direction; The monitoring upper device receives the first monitoring signal, in a first monitoring trigger layer, through first risk-oriented conditional matching analysis of the trigger boundary condition, non-matching pruning of the monitoring mode is performed, and a first monitoring instruction is determined. According to the first monitoring instruction, directional monitoring driving of the monitoring array is performed, and first monitoring data is determined.

8. The method of claim 7, wherein the powder spraying process of the automobile wheel hub trim is monitored by using a camera and a computer program. After determining the first monitoring data, the following steps are included: ​ In a second verification judgment layer, through matching analysis of the first risk orientation and the verification boundary condition, non-matching pruning of the monitoring element graph is performed, and a second verification subgraph is determined. The first monitoring data is returned, the second verification subgraph is used as the monitoring range, abnormality judgment based on the graph element is performed, and a first monitoring result is generated.

9. A process monitoring method for a powder spraying of an automobile wheel cover according to claim 8, wherein According to the first monitoring result, a first powder spraying state biasing instruction is generated. The powder spraying monitoring central control issues the first powder spraying state biasing instruction, and performs powder spraying control alarm and feedback regulation of powder spraying working conditions.

10. A powder spraying process monitoring system for automotive wheel hub trim, characterized by, The system is used to implement the powder spraying process monitoring method of the automobile hub decoration part according to any one of claims 1 to 9, and the system comprises: A powder spraying monitoring sequence determination module is used to obtain the geometric structure and coating information of the target decoration part, plan and locate the monitoring points of the powder spraying process cycle, and determine the powder spraying monitoring sequence, wherein the powder spraying mode of the whole cycle is single-layer powder spraying or composite powder spraying. A monitoring upper device construction module is used to plan the monitoring mode and the monitoring element graph based on the powder spraying scene of the target decoration part, construct the monitoring upper device, and embed the monitoring upper device in the powder spraying monitoring central control. A polling monitoring control module is used to brake the powder electrostatic spraying equipment according to the powder spraying process cycle, and perform polling monitoring control based on the risk points in the cycle by combining the first register and the monitoring upper device.

Images