Self-stabilizing floating ball device, blow mold, preparation method and method for inhibiting evaporation of reservoir

Abstract

The invention relates to the technical field of water resource saving and protection, and discloses a self-stabilizing floating ball device, a blow mold, a preparation method and a reservoir evaporation inhibiting method.The device is formed by connecting an upper shell and a lower shell, the upper shell is a sealed main buoyancy cabin, the outer surface of the upper shell is in a dark color, and the lower shell is provided with a water inlet hole to form an open type water ballast tank, and the outer surface of the lower shell is in a light color; automatic ballasting and gravity center lowering are achieved by injecting water, and a tumbler type self-stabilizing structure is formed. The preparation method comprises the steps of split blow molding, assembling and annealing treatment in a movable annealing box. According to the use method, the floating balls are arranged to form the evaporation-inhibiting covering layer, and the failed floating balls are automatically monitored and positioned based on the image recognition technology by utilizing color comparison of the upper shell and the lower shell. The problems that a traditional floating ball is poor in stability and low in production operation and maintenance efficiency are solved, and persistent stability and intelligent operation and maintenance of steam suppression coverage are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of water resource conservation and protection, and particularly relates to a self-stabilizing floating ball device, a blow molding die, a preparation method and a method for inhibiting evaporation of a reservoir. BACKGROUND

[0002] The ineffective evaporation of water storage bodies such as reservoirs and lakes is one of the important ways of water resource loss. In order to reduce such evaporation loss, using physical covering method to block sunlight and air circulation on the water surface is a direct and effective means. Among them, using a large number of floating balls floating on the water surface to form a covering layer is concerned due to its relatively controllable cost and good adaptability.

[0003] At present, the existing schemes in this technical field mainly exist in the following types:

[0004] The first type is a traditional hollow sealed floating ball. This type of floating ball is usually a completely sealed hollow plastic ball, and a counterweight is attached to the bottom to try to maintain its stable posture. For example, Chinese patent CN105905247A discloses a hollow floating ball for preventing evaporation of water surface of a plain reservoir in a dry area, which is made of polyolefin material and has a light gray appearance to reduce heat absorption. However, this design has significant defects: the center of gravity is still near or above the geometric center of the ball, which is prone to rolling, displacement or collision under the action of wind and waves, resulting in gaps in the water surface covering layer and a sharp decrease in evaporation inhibition effect; at the same time, the sealed structure formed in one piece makes the production mold complex and costly, and the internal water is difficult to repair after failure, which is basically a disposable product.

[0005] The second type is a floating cake or floating plate covering system. This type of system uses a large area of continuous or spliced floating plate to cover the water surface, sometimes combined with photovoltaic panels (photovoltaic evaporation inhibition). Although it has good continuity of coverage, it has poor adaptability to water level changes and is easily damaged as a whole in strong winds and waves, and is extremely inconvenient to install, remove and maintain, and the initial investment and maintenance cost is very high, making it difficult to be applied on a large scale in large reservoirs.

[0006] The third type is a floating ball structure with specific functions. There are some floating balls designed to solve other technical problems in the prior art, such as a floating ball switch for water pump dry running prevention (such as CN222686893U) or a floating body structure for offshore floating foundation (such as CN223148653U). The design goal of these floating balls is not large-scale water evaporation inhibition, and their structure either does not consider the group stability and mutual influence after large-scale deployment, or the structure is complex and expensive, which cannot meet the core requirements of low cost, high reliability and easy maintenance required for reservoir evaporation inhibition.

[0007] In addition, the prior art also has obvious shortcomings in the mass production and operation and maintenance of the floating ball. The traditional blow molding product needs to be annealed to eliminate internal stress, which is usually carried out in a fixed workshop, with high energy consumption and long cycle, and involves secondary transportation from the factory to the reservoir, increasing the carbon footprint and cost. In terms of operation and maintenance monitoring, the current main method is to rely on manual inspection to find failed (such as water sinking or tilting) floating balls, which is low in efficiency and high in cost, and it is difficult to achieve real-time and comprehensive monitoring of large water surface areas.

[0008] In summary, the water surface evaporation suppression floating ball device in the prior art uses closed unit floating to cover the water surface to achieve the effect of suppressing evaporation, does not fully utilize the characteristics of water and the interaction between the floating ball to achieve the optimal effect, and generally has the common problems of insufficient wind and wave resistance stability, low efficiency of mass production and deployment, high full life cycle operation and maintenance cost, lack of intelligent monitoring means, etc. SUMMARY

[0009] The present application provides a self-stabilizing floating ball device, a blow molding mold, a preparation method and a method for suppressing evaporation of a reservoir to solve the above problems.

[0010] In a first aspect, the present application provides a self-stabilizing floating ball device, comprising an upper shell and a lower shell connected to each other: The inside of the upper shell is a sealed main buoyancy cabin, and the outer surface is dark; The upper shell is a flat spherical shape, hollow, provides the main buoyancy, and is separated from the lower shell; the inside of the lower shell constitutes an open ballast water cabin, the side wall and / or the bottom thereof is provided with a plurality of water inlet holes allowing water to enter, and the outer surface is light-colored; The configuration of the ballast water cabin enables the floating ball device to automatically inject ballast water to lower the center of gravity and achieve self-stabilization when deployed on the water surface, while having the performance of resisting wind, waves and rolling.

[0011] When the device is deployed on the surface of a reservoir, its initial orientation is typically that the lower shell is submerged under its own weight and buoyancy. At this time, external water flows naturally into the ballast tanks of the lower shell through the inlet. As water is continuously injected, the volume of water in the ballast tanks gradually increases, significantly lowering the center of gravity of the entire buoy device. This process is automatic and requires no external intervention. Eventually, the entire device stabilizes in an equilibrium state: most of the buoyancy is provided by the sealed main buoyancy tank of the upper shell, while most of the mass (weight) is provided by the water in the ballast tanks of the lower shell. This "light on top, heavy on bottom" and "buoyant on top, ballasted on bottom" configuration makes the overall center of gravity of the device much lower than its center of buoyancy, producing a mechanical effect similar to a "roly-poly toy," i.e., a self-stabilizing effect. When encountering disturbances from wind and waves, the device generates a restoring torque, enabling it to resist tilting and rolling, and quickly return to an upright posture after the disturbance ends. This allows the surface covering layer, composed of thousands of such floats, to maintain a uniform and dense distribution over a long period, effectively shielding the water surface and reducing evaporation channels, thus achieving a long-lasting and efficient evaporation suppression effect. The use of ambient water as ballast material through open ballast tanks automates and reduces the cost of ballast loading. By physically lowering the center of gravity through water injection ballast, the technical challenges of high center of gravity and easy capsizing associated with traditional sealed floats are fundamentally solved, resulting in excellent dynamic stability. The contrasting colors of the upper and lower shells, besides functional considerations, also lay the foundation for subsequent visual monitoring.

[0012] In one optional embodiment, the upper housing and the lower housing are connected by circumferentially distributed snap-fit ​​components. The snap-fit ​​components include hooks located on the edge of the upper housing and seats located on the edge of the lower housing, and are locked by vertical pressing.

[0013] In one alternative embodiment, the upper shell and the lower shell have a locally reinforced structure formed by a blow molding die, with a thickness greater than that of the middle of the shell, and the parting line of the upper shell is located at the equatorial plane of the float.

[0014] In one alternative embodiment, the water inlet hole is a through hole formed by a sliding pin mechanism integrated in the mold during the blow molding of the lower shell, with a diameter of 3 mm to 5 mm.

[0015] In one alternative implementation, the light color is white or light gray, and the dark color is black or dark gray. The color contrast between the upper and lower shells allows the buoy's attitude on the water surface to be monitored using image recognition technology.

[0016] Secondly, the present invention also provides a blow molding die for preparing the self-stabilizing float device, wherein the die opening of the blow molding die adopts an alternating upper concave and lower convex cutting edge, and employs extrusion shearing; and further includes A sliding pin-type opening mechanism, comprising a pin-shaped structure with a sliding shaft integrated into the lower housing mold; Temperature control system for individual temperature control in the mold parting line area.

[0017] Thirdly, the present invention also provides a method for preparing the self-stabilizing float device, comprising the following steps: The upper and lower shells are formed using a blow molding process; The formed upper and lower shells are assembled using a connecting mechanism; The assembled float device is placed in a movable annealing chamber and annealed according to a predetermined temperature profile to eliminate internal stress.

[0018] In one optional embodiment, the step of placing the assembled float device in a movable annealing box and annealing it according to a predetermined temperature curve to eliminate internal stress is completed in the annealing box mounted on a transport vehicle during the transport of the float device to the reservoir deployment point, thereby integrating production, annealing and logistics.

[0019] Fourthly, the present invention also provides a method for suppressing reservoir evaporation, using the aforementioned self-stabilizing float device, comprising the following steps: The float device is placed on the surface of the reservoir to ensure that the lower shell enters the water first, so that the ballast water tank is automatically filled with water through the inlet hole; The monitoring system, based on image recognition, acquires images of the water surface float array and automatically identifies and locates failed floats that have rolled or tilted based on the visible ratio of the dark upper shell to the light lower shell in the image.

[0020] In one alternative implementation, after identifying a malfunctioning float, the process further includes: An unmanned vessel equipped with visual positioning capabilities was dispatched to the location of the failed buoy for automatic retrieval.

[0021] In one alternative implementation, the buoy device is deployed using a deployment vessel or vehicle with an automatic deployment function, and the deployment equipment controls the spacing between adjacent buoys to be dense according to a preset deployment density. Attached Figure Description

[0022] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0023] Fig. 1This is a schematic diagram of the structure of a self-stabilizing float device according to an embodiment of the present invention; Fig. 2 This is a schematic diagram of the lower shell structure in a self-stabilizing float device according to an embodiment of the present invention; Fig. 3 This is a schematic diagram of the lower shell of a self-stabilizing float device according to an embodiment of the present invention after water has entered it.

[0024] Explanation of reference numerals in the attached figures: 1. Upper shell; 2. Lower casing; 3. Water inlet. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] Ineffective evaporation from water bodies such as reservoirs and lakes is a significant pathway for water resource loss. To reduce this evaporation loss, physical covering methods to block sunlight and airflow across the water surface are a direct and effective approach. Among these methods, using a large number of floating buoys to form a covering layer has attracted attention due to its relatively controllable cost and good adaptability.

[0027] Currently, the existing solutions in this technical field mainly fall into the following categories: The first type is the traditional hollow sealed float. These floats are typically completely sealed hollow plastic spheres, with counterweights added to the bottom to attempt to maintain their stability. For example, existing technology discloses a hollow float for preventing evaporation from the surface of reservoirs in drought-stricken plains, made of polyolefin material, with a light gray appearance to reduce heat absorption. However, this design has significant drawbacks: its center of gravity remains near or slightly above the sphere's geometric center, making it highly susceptible to tumbling, displacement, or collisions under the influence of wind and waves, leading to voids in the water surface cover and a sharp decrease in evaporation suppression. Furthermore, the one-piece sealed structure makes production molds complex and costly, and internal water ingress after failure is difficult to repair, essentially making it a disposable product.

[0028] The second type is the floating cake or floating plate covering system. This type of system uses large-area continuous or spliced ​​floating plates to cover the water surface, and sometimes it is combined with photovoltaic panels (photovoltaic evaporation suppression). Although it has good coverage continuity, it has poor adaptability to water level changes, is easily damaged in strong winds and waves, and is extremely inconvenient to install, dismantle and maintain. Moreover, the initial investment and maintenance costs are very high, making it difficult to apply on a large scale in large reservoirs.

[0029] The third category consists of float structures with specific functions. Existing technologies include some floats designed to solve other technical problems, such as float switches for preventing pump dry running, or floating structures for offshore floating foundations. These floats are not designed for large-scale surface evaporation suppression; their structures either fail to consider the group stability and mutual influences after large-scale deployment, or are complex and expensive, failing to meet the core requirements of low cost, high reliability, and easy maintenance for reservoir evaporation suppression.

[0030] Furthermore, existing technologies have significant shortcomings in the large-scale production and operation and maintenance of buoys. Traditional blow-molded products require annealing to eliminate internal stress, a process typically carried out in a fixed workshop, which is energy-intensive, time-consuming, and involves secondary transportation from the factory to the reservoir, increasing carbon footprint and cost. In terms of operation and maintenance monitoring, current methods mainly rely on manual inspections to detect malfunctioning buoys (such as those that have sunk or tilted due to water ingress), which is inefficient, costly, and makes it difficult to achieve real-time, comprehensive monitoring of large water areas.

[0031] In summary, existing surface evaporation suppression float devices generally suffer from common problems such as insufficient stability against wind and waves, low efficiency in large-scale production and deployment, high operation and maintenance costs throughout the entire life cycle, and a lack of intelligent monitoring methods.

[0032] The following is combined with Figs. 1 to 3 The following describes embodiments of the present invention.

[0033] According to an embodiment of the present invention, a self-stabilizing buoy device is provided, comprising an upper shell 1 and a lower shell 2 connected to each other. The upper shell 1 has a sealed main buoyancy chamber inside, and its outer surface is dark-colored. The lower shell 2 has an open ballast water chamber inside, and its side walls and / or bottom are provided with a plurality of water inlet holes 3 that allow water to enter. Its outer surface is light-colored. The configuration of the ballast water chamber enables the buoy device to automatically inject ballast water to lower the center of gravity when deployed on the water surface, thereby achieving self-stabilization.

[0034] The upper shell 1 is oblate or hemispherical dome-shaped, with a completely sealed cavity inside, forming the main buoyancy chamber that provides the primary buoyancy. The main buoyancy chamber is filled with air or other light gases to ensure the overall density of the device is less than water. The outer surface of the upper shell 1 is dark-colored, such as black, dark gray, or dark green, primarily to reflect solar radiation and reduce heat absorption by the device itself, thereby indirectly reducing heat conduction to the lower water layer. The lower shell 2 is bowl-shaped or an inverted hemispherical shell, with its top opening edge merging with the edge of the upper shell 1. The interior space of the lower shell 2 is a downward-opening chamber that forms the ballast water tank. The ballast water tank is not sealed but communicates with the external water body through multiple water inlets 3 on the side walls and bottom of the lower shell 2. The outer surface of the lower shell 2 is light-colored, such as white, light gray, or pale yellow, creating a striking visual contrast with the dark color of the upper shell 1. The water inlets 3 can also be individually located on the side walls or bottom of the lower shell 2.

[0035] The upper shell 1 and the lower shell 2 are fixed together by a connecting mechanism to form a complete float. The specific method of connection can be any method known to those skilled in the art that can achieve a stable connection, such as, but not limited to, bonding, welding, bolting, or snap-fitting.

[0036] The working principle and self-stabilizing effect of this float device are as follows: When the device is deployed on the surface of a reservoir, its initial orientation is typically that the lower shell 2 is submerged in water due to its own weight and buoyancy. At this time, external water flows naturally into the ballast water tank of the lower shell 2 through the water inlet 3. As water is continuously injected, the water volume in the ballast water tank gradually increases, thereby significantly lowering the center of gravity of the entire buoy device. This process is automatic and requires no external intervention. Eventually, the entire device will stabilize in an equilibrium state: most of the buoyancy is provided by the sealed main buoyancy tank of the upper shell 1, while most of the mass (weight) is provided by the water in the ballast water tank of the lower shell 2. This "light on top, heavy on bottom" and "buoyant on top, ballasted on bottom" configuration makes the overall center of gravity of the device much lower than its center of buoyancy, producing a mechanical effect similar to a "roly-poly toy," i.e., a self-stabilizing effect. When encountering wind and waves, the device generates a restoring torque, enabling it to resist tilting and rolling, and quickly return to an upright posture after the disturbance ends. This allows the water surface covering layer, composed of thousands of such floats, to maintain a uniform and dense distribution over a long period of time, effectively blocking the water surface and reducing the channels for water vapor evaporation, thereby achieving a long-lasting and efficient purpose of suppressing evaporation.

[0037] This embodiment utilizes ambient water as ballast material through an open ballast tank, achieving automation and cost reduction in ballast loading. By physically lowering the center of gravity through water injection ballast, the technical challenges of high center of gravity and easy capsizing associated with traditional sealed floats are fundamentally solved, resulting in excellent dynamic stability. The contrasting colors of the upper and lower shells, besides functional considerations, also lay the foundation for potential subsequent visual monitoring.

[0038] In one embodiment, the upper housing 1 and the lower housing 2 are connected by a circumferentially distributed snap-fit ​​assembly. The snap-fit ​​assembly includes a hook located on the edge of the upper housing 1 and a seat located on the edge of the lower housing 2, and is locked by vertical pressing.

[0039] In this embodiment, the upper housing 1 and the lower housing 2 are mechanically connected and locked by circumferentially distributed snap-fit ​​assemblies. The snap hooks are fixedly disposed on the inner side of the lower edge of the upper housing 1 or on the mating surface. The ends of the snap hooks are designed with outward protrusions or barbs. The snap seat is fixedly disposed on the outer side of the upper edge of the lower housing 2 or on the mating surface, its position corresponding to the snap hook. A groove or cavity matching the shape of the snap hook is formed inside the snap seat. The snap-fit ​​assemblies are evenly distributed along the circumference of the mating surfaces of the upper and lower housings 2. Depending on the diameter of the float, typically 6 to 8 sets of snap-fit ​​assemblies are sufficient to provide a balanced and reliable connection force.

[0040] During assembly, align the upper housing 1 with the lower housing 2, ensuring that the circumferential hooks are roughly aligned with the mounting base. Apply downward pressure axially (i.e., perpendicular to the equatorial plane of the float). The guide ramp of the hook will contact the inlet edge of the mounting base, undergoing elastic deformation under pressure and sliding into the mounting base. When the barb of the hook has completely passed the locking shoulder within the mounting base, it returns to its original shape due to the elasticity of the material, and the barb and the locking shoulder form a mechanical interlock.

[0041] In one embodiment, the parting line of the upper shell 1 and the lower shell 2 has a locally reinforced structure formed by a blow molding die, with a thickness greater than that of the middle of the shell, and the parting line of the upper shell 1 is located at the equatorial plane of the float.

[0042] In blow molding, the preform is squeezed, cut, and fused at the mold's closing opening, forming a parting line that surrounds the product. This line is usually the weakest point in the overall structural strength and resistance to environmental stress cracking of the product. For reservoir buoys that need to withstand wind, waves, sun exposure, and collisions on the water surface for extended periods, the weak parting line of traditional blow-molded parts is prone to cracking, leading to water ingress and failure of the main buoyancy chamber, which is a major bottleneck restricting their service life. The solution in this embodiment is to structurally strengthen the parting line. Specifically, during blow molding, the mold's closing opening for the upper shell 1 and lower shell 2 employs a special design, making the wall thickness at the parting line significantly greater than the wall thickness of the non-parting area in the middle of the shell. For example, if the main wall thickness of the upper shell 1 is designed to be 1.5 mm, the wall thickness of the parting line area can be increased to 2.0-2.3 mm through mold design. This localized strengthening structure is not added later but is an integral structure directly formed by the blow molding mold during the molding process.

[0043] This increase in thickness is achieved by optimizing the mold closing structure. In a preferred embodiment, the closing openings of the upper and lower molds are not simply planar but designed as staggered cutting edges with an upper concave and a lower convex shape, or a structure with a compression shearing bevel.

[0044] At the moment of mold closing, the cutting edges of the upper and lower molds interlock, compressing and containing more molten billet material within the mold-closing line area, rather than completely cutting it off as flash. This physically increases the material accumulation and thickness at that point. Simultaneously, this compression action causes the material molecular chains at the mold-closing line to become more fully entangled and fused under high temperature and pressure, improving the weld strength and crystallinity, and fundamentally enhancing its mechanical properties.

[0045] This embodiment transforms the inherent weakness (mold line) of traditional blow molding process into a structural strength, thereby improving the overall impact fatigue life of the float device without increasing the total weight of materials or complex post-processing.

[0046] In one embodiment, the water inlet 3 is a through hole formed by a sliding pin mechanism integrated in the mold during the blow molding of the lower housing 2, with a diameter of 3 mm to 5 mm.

[0047] In traditional manufacturing processes, sidewall openings such as water inlet holes 3 typically require secondary processing steps such as drilling, punching, or hot-melt piercing after the plastic product has been blow-molded. This "post-processing" model has significant drawbacks: low production efficiency, increasing production cycle time and labor costs; inconsistent hole quality, easily resulting in burrs, cracks, or stress concentration points; poor hole shape consistency, and difficulty in achieving high-density, high-precision hole group processing on curved shells. For anti-evaporation floats that require large-scale production and dozens of water inlet holes 3 on each lower shell 2, the traditional method is the main cost and quality bottleneck.

[0048] This embodiment uses a blow molding mold for forming the lower housing 2, and integrates a sliding shaft needle mechanism. This mechanism mainly consists of a needle-shaped component and a sliding shaft (or cylinder) that drives its reciprocating motion. The material and tip shape of the needle-shaped component are specially designed to have high strength, high heat resistance, and low adhesion.

[0049] This innovative process is carried out simultaneously with the blow molding cycle, and the specific steps are as follows: Step 1: Mold Closure and Inflation. The mold is closed, and the parison is clamped in the mold opening. Compressed air is then introduced into the parison, causing it to cool and solidify against the mold cavity wall (including the pre-set needle-like tip position), initially forming the bowl-shaped structure of the lower shell 2.

[0050] Step Two: Sliding Shaft Ejection and Puncture. Within a critical time window after the preform has inflated but before it has fully cooled and solidified, the control system drives the sliding shaft forward. The needle-like component integrated within the mold then extends precisely and at high speed along a direction perpendicular to the preform wall, its tip piercing the semi-molten preform wall.

[0051] Step 3: Pressure Holding and Retraction. The needle-like component is held briefly at the penetration position (pressure holding), allowing the plastic material around the hole to redistribute and fuse under pressure and residual heat, forming a smooth inner wall. After the lower shell 2 body has fully cooled and solidified, the sliding shaft drives the needle-like component to retract to its original position inside the mold.

[0052] Step 4: Mold Opening and Part Removal. The mold is opened, and the formed lower shell 2 is ejected. At this time, the neatly arranged water inlet holes 3 have been simultaneously formed at the preset positions on the side wall of the shell, requiring no further processing.

[0053] In one embodiment, the light color is white or light gray, and the dark color is black or dark gray. The color contrast between the upper shell 1 and the lower shell 2 allows the attitude of the buoy on the water surface to be monitored using image recognition technology.

[0054] According to an embodiment of the present invention, in another aspect, a blow molding die is also provided for preparing a self-stabilizing float device, wherein the mold opening of the blow molding die adopts an alternating upper concave and lower convex cutting edge, and employs extrusion shearing; it also includes... A sliding pin-type opening mechanism, comprising a pin-shaped structure with a sliding shaft integrated into the lower housing mold; Temperature control system for individual temperature control in the mold parting line area.

[0055] By setting up alternating concave and convex cutting edges, a mechanical interlocking effect is generated during mold closing, increasing the material thickness at the mold parting line; the extrusion shearing design allows excess material to be squeezed inward during mold closing, forming a reinforcing rib structure; the precise temperature control system allows for zoned temperature control of the mold, with separate temperature control for the mold parting line area, improving the material crystallinity; preferably, the mold parting line of the upper shell is parallel to the horizontal plane, which can enhance the collision resistance of adjacent spheres.

[0056] By integrating a needle-like structure with a sliding shaft into the lower shell mold, the water inlet hole is formed simultaneously with mold closing. Specifically, when the mold closes, the needle-like structure extends, penetrates the blank wall, and retracts after pressure holding and cooling to form a regular water inlet hole. This design can precisely control the hole diameter and distribution density.

[0057] According to an embodiment of the present invention, in another aspect, a method for preparing a self-stabilizing float device is also provided, comprising the following steps: The upper shell 1 and the lower shell 2 are formed separately using a blow molding process; The formed upper shell 1 and lower shell 2 are assembled using a connecting mechanism; The assembled float device is placed in a movable annealing chamber and annealed according to a predetermined temperature profile to eliminate internal stress.

[0058] This embodiment provides a method for preparing a self-stabilizing float device. This method, through an optimized process flow, organically combines modular manufacturing, assembly, and post-processing, aiming to efficiently and with high quality produce a stable anti-evaporation float. The method mainly includes the following three core steps: S10, S20, and S30.

[0059] S10: Use blow molding process to form the upper shell 1 and the lower shell 2 respectively; This step is the component manufacturing stage. Conventional blow molding equipment is used, with dedicated blow molds for both the upper shell 1 and the lower shell 2. Pre-mixed thermoplastic raw materials (such as high-density polyethylene, HDPE) are heated, melted, and extruded to form preforms, which are then placed into their respective molds. After closing the molds, compressed air is injected into the preforms, causing them to expand and cool against the inner wall of the mold to solidify. The molds are then opened, and the products are removed, thus obtaining the upper shell 1 blank and the lower shell 2 blank, each with its basic structural shape.

[0060] Preferably, the thermoplastic raw material is: Main material: High-density polyethylene (HDPE), melt index 0.8-1.2 g / 10 min (190℃, 2.16 kg). Anti-aging system: Carbon black: 2.5-3.0% (by weight), providing UV protection; Succinate: 0.4-0.5% (by weight), as a light stabilizer; Organic phosphite: 0.1-0.2% (by weight), as an antioxidant; Color masterbatch: Upper shell: Add light gray masterbatch (TiO2-based), 4-6% addition amount; Lower shell: Add dark gray masterbatch (carbon black base), 3-5% addition amount.

[0061] The blow molding process includes: preform temperature: HDPE, 190-210℃, blow molding pressure: 0.8-1.2MPa, cooling time: 10-60s (adjusted according to wall thickness), and clamping force: 60-80kg (for Φ10mm floats).

[0062] S20: Assemble the formed upper shell 1 and lower shell 2 through a connecting mechanism; This step is the component assembly stage. The upper shell 1 and lower shell 2 obtained in step S10 are transported to the assembly station. They are combined into a complete float device through a predetermined connecting mechanism. The connecting mechanism can be one of several methods commonly used in the art to achieve a stable connection between the two, such as using a snap-fit ​​structure for locking, using a threaded structure for screwing, or using a hot plate to heat the mating surfaces for welding. The goal of this step is to achieve a physical connection and seal between the two shells, forming an initial float with the basic functional structure of a main buoyancy chamber and a ballast water tank.

[0063] S30: Place the assembled float device in a movable annealing chamber and anneal it according to the predetermined temperature profile. Portable Annealing Chamber: The annealing chamber is not a large, fixed annealing furnace in the workshop, but rather an independent, portable unit with complete heating, temperature control, and heat preservation functions. Its chamber typically features a double-layered insulation structure and integrates heating units such as heating wires and PTC ceramic heating elements, as well as high-precision temperature sensors and PID temperature controllers. The chamber is equipped with wheels at the bottom or can be directly mounted on a transport vehicle.

[0064] Annealing process: The batch of float devices assembled in step S20 is installed into the annealing chamber. After closing the chamber door, the annealing program is started, and the controller automatically operates according to the predetermined temperature profile. A typical annealing profile suitable for HDPE material is used as an example: Heating phase: At a rate not exceeding 50°C / hour, uniformly raise the temperature inside the chamber from room temperature to the target annealing temperature, for example, 95 ± 2°C.

[0065] Holding stage: Hold at the target annealing temperature for 2.5 to 3 hours. During this process, the plastic molecular chains gain sufficient mobility, and the internal stress generated during blow molding and cooling is fully relaxed.

[0066] Cooling phase: Turn off active heating, control the cooling rate (e.g., ≤30°C / hour) or allow the chamber to cool naturally to reduce the temperature to below 40°C.

[0067] After annealing, the residual stress inside the float device is significantly eliminated. This effectively prevents the float from stress cracking, deformation, or performance degradation due to changes in ambient temperature, sunlight, or stress during long-term outdoor use, thereby significantly improving the dimensional stability and long-term durability of the product.

[0068] If the material is PP, heat it to 100±2℃, keep it at that temperature for 1.5-2 hours, and then cool it down with the container.

[0069] In one embodiment, the assembled float device is placed in a movable annealing chamber and annealed according to a predetermined temperature profile to eliminate internal stress. This annealing process is completed in the annealing chamber mounted on a transport vehicle during the transport of the float device to the reservoir deployment point, thus integrating production, annealing, and logistics. The power system can employ a lithium battery pack combined with a solar charging system.

[0070] According to an embodiment of the present invention, another aspect provides a method for suppressing reservoir evaporation, using a self-stabilizing float device, comprising the following steps: The float device is placed on the surface of the reservoir to ensure that the lower shell 2 enters the water first, so that the ballast water tank is automatically filled with water through the water inlet 3. The monitoring system based on image recognition acquires images of the water surface float array and automatically identifies and locates failed floats that have rolled or tilted based on the visible ratio of the dark upper shell 1 and the light lower shell 2 in the image.

[0071] This embodiment provides a method for suppressing reservoir evaporation using a self-stabilizing float device. The core of this method lies in not only achieving the physical evaporation suppression function of the float, but also realizing automated and visualized monitoring of the operational status of a large-scale float array through an intelligent monitoring system. This solves the maintenance problems of low efficiency and high cost associated with traditional manual inspections. The method mainly includes the following two core steps, U10 and U20.

[0072] U10: Deploy the float device on the reservoir surface to ensure that the lower shell 2 enters the water first; This step is the initial deployment phase. A large number of self-stabilizing buoy devices are deployed onto the surface of the target reservoir using appropriate methods (such as manual deployment, deployment vessels, or automatic deployment equipment). During deployment, the attitude should be controlled to ensure that the lower shell 2 of the buoy enters the water first or vertically. Once the lower shell 2 contacts the water surface, external water flows naturally into the ballast water tank through its inlet 3. As ballast water is injected, the buoy's center of gravity lowers, automatically adjusting to a stable, upright floating posture. The darker portion of its upper shell 1 is mainly exposed above the water surface, while the lighter portion of the lower shell 2 is submerged or only visible near the waterline. The large number of buoys forms a high-coverage anti-evaporation layer on the water surface.

[0073] U20: Automated monitoring and failure identification based on image recognition; Monitoring System Composition: The image recognition-based monitoring system mainly consists of an image acquisition unit and an image processing unit. The image acquisition unit can be a fixed camera deployed at a high point on the shore, a drone, or a satellite over the reservoir. The image processing unit can be a local server or a cloud computing platform.

[0074] Image acquisition and feature extraction: The system periodically or in real-time controls the image acquisition unit to acquire high-definition images or video streams covering the entire float array. This is achieved through the striking color contrast between the upper housing 1 (dark) and the lower housing 2 (light) of the float device. Failure detection algorithm principle: The image processing unit runs a specific image recognition algorithm (such as a program developed based on the OpenCV library). Its core logic for identifying and locating failed floats lies in analyzing the statistical characteristics of color pixels within a single float image region. Normal state criterion: For a preset image analysis window containing a single floating ball, the algorithm calculates the area ratio occupied by dark pixels (corresponding to upper shell 1). When this ratio is higher than a preset high threshold (e.g., >85%), the floating ball is determined to be in an upright and normal state.

[0075] Failure Criteria: When a buoy tilts severely or rolls completely due to internal leakage, connection failure, or external impact, a larger area of ​​its light-colored lower shell 2 will be exposed above the water surface. In this case, the proportion of light-colored pixels within the same analysis window will significantly increase. The buoy is considered a "failed buoy" when the algorithm detects that the proportion of dark pixels in a target area is below a preset low threshold (e.g., <60%), or when light-colored pixels form a large continuous area.

[0076] Location: At the same time, the algorithm records the pixel coordinates of the abnormal area in the image and converts them into the actual geographical coordinates of the reservoir (such as GPS coordinates) through georeferencing technology, thereby achieving precise location of the failed buoy.

[0077] In one embodiment, after identifying a faulty float, the method further includes: Dispatch unmanned surface vessels (USVs) equipped with visual positioning capabilities to the location of the defunct buoy for automated retrieval. Alternatively, drones can be used to flip the buoy.

[0078] In one embodiment, the deployment of the buoy device is carried out by a deployment vessel or vehicle with automatic deployment function. The deployment equipment controls the spacing between adjacent buoys to be dense according to a preset deployment density, for example, 10 cm to 15 cm.

[0079] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A self-stabilizing float device, comprising an upper shell (1) and a lower shell (2) connected to each other, characterized in that: The upper shell (1) has a sealed main buoyancy chamber inside, and its outer surface is dark. The lower shell (2) has an open ballast water tank inside, and its side walls and / or bottom are provided with multiple water inlet holes (3) that allow water to enter. The outer surface is light-colored. The upper shell (1) is flattened spherical and hollow, providing the main buoyancy and separated from the lower shell; the configuration of the ballast water tank enables the float device to automatically inject ballast water to lower the center of gravity when deployed on the water surface, achieving self-stabilization, and at the same time has the performance of resisting wind, waves and rollover.

2. The self-stabilizing float device according to claim 1, characterized in that, The upper housing (1) and the lower housing (2) are connected by a circumferentially distributed snap fastener assembly. The snap fastener assembly includes a hook on the edge of the upper housing (1) and a seat on the edge of the lower housing (2). The snap fastener assembly is locked by pressing vertically.

3. The self-stabilizing float device according to claim 1, characterized in that, The upper shell (1) and the lower shell (2) have a locally reinforced structure formed by a blow molding die, with a thickness greater than that of the middle part of the shell, and the mold line of the upper shell (1) is located at the equatorial plane of the float.

4. The self-stabilizing float device according to claim 3, characterized in that, The water inlet hole (3) is a through hole formed by a sliding pin mechanism integrated in the mold during the blow molding of the lower shell (2), with a diameter of 3 mm to 5 mm.

5. The self-stabilizing float device according to claim 1, characterized in that, The light color is white or light gray, and the dark color is black or dark gray. The color contrast between the upper shell (1) and the lower shell (2) allows the attitude of the buoy on the water surface to be monitored by image recognition technology.

6. A blow molding die for manufacturing the self-stabilizing float device according to any one of claims 1 to 5, characterized in that, The blow molding die has an alternating concave-convex cutting edge at the mold opening and employs extrusion shearing; it also includes... A sliding pin-type opening mechanism, comprising a pin-shaped structure with a sliding shaft integrated into the lower housing mold; Temperature control system for individual temperature control in the mold parting line area.

7. A preparation method for preparing the self-stabilizing float device according to any one of claims 1 to 5, characterized in that, Includes the following steps: The upper shell (1) and the lower shell (2) are formed using a blow molding process. The formed upper shell (1) and lower shell (2) are assembled by a connecting mechanism; The assembled float device is placed in a movable annealing chamber and annealed according to a predetermined temperature profile to eliminate internal stress.

8. The preparation method according to claim 7, characterized in that, The annealing process, which involves placing the assembled float device in a movable annealing box and annealing it according to a predetermined temperature curve to eliminate internal stress, is completed in the annealing box mounted on a transport vehicle during the transport of the float device to the reservoir deployment point.

9. A method for suppressing reservoir evaporation, using a self-stabilizing float device as described in any one of claims 1 to 5, characterized in that, Includes the following steps: The float device is placed on the surface of the reservoir to ensure that the lower shell (2) enters the water first, so that the ballast water tank is automatically filled with water through the water inlet (3); The monitoring system based on image recognition acquires images of the water surface float array and automatically identifies and locates failed floats that have rolled or tilted based on the visible ratio of the dark upper shell (1) and the light lower shell (2) in the image.

10. The method for suppressing reservoir evaporation according to claim 9, characterized in that, After identifying a faulty float, the following further steps are included: An unmanned vessel equipped with visual positioning capabilities was dispatched to the location of the failed buoy for automatic retrieval.

11. The method for suppressing reservoir evaporation according to claim 9, characterized in that, The buoy devices are deployed using deployment vessels or vehicles with automatic deployment capabilities, and are arranged in a close-packed manner to increase the water surface coverage.

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