Train carriage leak repairing spraying device and method

Abstract

The invention discloses a train carriage leak repairing spraying device and method. The defect that in the prior art, a special scheme is lacked in the aspects of accurate on-demand matching and efficient mixing of leak repairing materials is overcome. The device comprises an independent two-component supply structure, an air jet mixer and a control unit. The feeding structure drives a conveying pump through a servo motor to achieve accurate feeding; the mixer is used for quickly and uniformly mixing the two-component materials by utilizing compressed air jet flow; the control unit can receive the gap characteristic signal and dynamically adjust the rotating speed of the motor so as to change the material ratio. According to the invention, self-adaptive accurate proportioning and efficient mixed spraying of the leak repairing material are realized.

Description

Technical Field

[0001] This invention relates to the field of railway vehicle maintenance technology, specifically to a leak-repair spraying device and method for train carriages. Background Technology

[0002] Railway freight trains, especially coal-carrying carriages, are prone to developing cracks in their bodies and unloading doors due to vibration and corrosion during long-term high-load operation. These cracks lead to cargo spillage, environmental pollution, and safety hazards, requiring timely and reliable repair. Currently, the mainstream repair method is still manual operation, which has many drawbacks such as low efficiency, inconsistent quality, high labor intensity, and difficulty in operating in harsh environments.

[0003] To improve the level of automation in operations, some mobile leak repair equipment or robotic systems have emerged in existing technologies. However, these solutions mostly focus on macro-level automation such as robotic arm trajectory control and mobile platform navigation, while exhibiting significant shortcomings in the core process that determines leak repair quality: the precise on-demand proportioning and efficient mixing of the leak repair material. Most equipment uses a fixed or preset ratio to output two-component materials, failing to dynamically adjust the ratio based on key characteristics such as the width and depth of the gap detected in real time. This can lead to material waste in small gaps and insufficient filling strength in large gaps. Furthermore, existing equipment often uses simple mechanical mixing or static mixers, which are insufficient to meet the second-level uniform mixing requirements of fast-curing two-component materials, and generally lack systematic solutions for special working conditions such as the tendency of high-viscosity materials to clog and poor flowability at low temperatures.

[0004] Therefore, there is an urgent need in this field for an intelligent special device that can deeply integrate gap feature recognition and thereby achieve adaptive and precise proportioning, high-speed uniform mixing and reliable spraying of the repair material, so as to overcome the technical bottleneck of existing technologies that rely on manual labor for quality and have extensive processes. Summary of the Invention

[0005] The purpose of this invention is to provide a train carriage leak repair spraying device and method to overcome the shortcomings of existing technologies in terms of the lack of a dedicated solution for the precise on-demand proportioning and efficient mixing of leak repair materials.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: This invention provides a leak repair spraying device for train carriages, comprising: a material supply structure, including a first component supply structure and a second component supply structure, both the first component supply structure and the second component supply structure including a storage tank, the storage tank being equipped with a heating device, the storage tank being connected to a delivery pump, and the delivery pump being connected to a servo motor; the storage tanks of the first component supply structure and the second component supply structure are respectively used to store two components of leak repair material. The ejection structure includes an air jet mixer, which is provided with a first inlet, a second inlet, and a compressed air inlet. The first inlet is connected to a delivery pump of a first component supply structure via a pipeline, the second inlet is connected to a delivery pump of a second component supply structure via a pipeline, and the compressed air inlet is connected to a compressed air tank via a pipeline. The other end of the air jet mixer is connected to a nozzle. The control unit is electrically connected to the servo motor of the material supply structure, the heating device, and the outlet valve of the compressed air tank, respectively. The control unit includes at least a proportioning control module. The ratio control module is used to receive detection signals characterizing the features of the gap to be repaired, and to determine the output ratio of the first repair material and the second repair material according to the detection signals in order to control the speed of the two servo motors.

[0007] According to one embodiment of the present invention, the proportioning control module is further configured to: control the two servo motors to operate at a first speed ratio when the detection signal indicates that the gap size is less than or equal to a first threshold; control the two servo motors to operate at a second speed ratio when the detection signal indicates that the gap size is greater than the first threshold; and simultaneously send an opening signal to the outlet valve of the compressed air tank to synchronously supply compressed air while the servo motors are operating.

[0008] According to one embodiment of the present invention, the first speed ratio is the ratio of the speed of the servo motor of the first component supply structure to the speed of the servo motor of the second component supply structure is 1:1, and the second speed ratio is the ratio of the speed of the servo motor of the first component supply structure to the speed of the servo motor of the second component supply structure is 1:1.5.

[0009] According to one embodiment of the present invention, when the two servo motors operate at a first speed ratio, the speed of both servo motors is 500 rpm; when the two servo motors operate at a second speed ratio, the speed of the servo motor of the first component supply structure is 500 rpm, and the speed of the servo motor of the second component supply structure is 750 rpm.

[0010] According to one embodiment of the present invention, the heating device includes a temperature sensor for monitoring the internal temperature of the storage tank and a heating actuator disposed on the outer wall of the storage tank. The control unit further includes a temperature control module, which is electrically connected to the temperature sensor and the heating actuator and is configured to: control the heating actuator to start when the temperature detected by the temperature sensor is lower than a first preset temperature; and control the heating actuator to stop when the temperature detected by the temperature sensor is higher than a second preset temperature.

[0011] According to one embodiment of the present invention, the air jet mixer includes a feeding structure, a premixing zone, and a mixing zone that are coaxially connected in sequence; the first feeding port and the second feeding port are disposed on the side wall of the feeding structure, and the compressed air inlet is disposed at the center of the end face of the feeding structure; a guide layer is disposed inside the feeding structure, and the first feeding port and the second feeding port are connected to the premixing zone through the guide layer, and a compressed air guide channel is formed between the compressed air inlet and the guide layer.

[0012] According to one embodiment of the present invention, the nozzle is a fan-shaped nozzle, the nozzle is connected to the outlet end of the air jet mixer via a quick-connect coupling, the nozzle has an ejection channel inside, and the ejection end of the nozzle has an arc-shaped guide surface.

[0013] According to one embodiment of the present invention, the control unit further includes a cleaning control module, which is configured to first control the delivery pump to stop after the spraying is completed, and maintain the outlet valve of the compressed air tank open for a preset time.

[0014] According to one embodiment of the present invention, the device further includes a frame, the inside of which is provided with a receiving space for a material supply structure and an ejection structure. A connecting plate is provided at the bottom of the frame, and a layered support frame is provided on the connecting plate. The storage tanks of the first component supply structure and the second component supply structure are placed on the upper layer of the layered support frame, and the servo motor and the delivery pump are placed on the lower layer.

[0015] This invention also provides a method for spraying repair coating on train carriages, using the train carriage repair coating device described above, comprising the following steps: receiving a detection signal characterizing the features of the gap to be repaired; determining the output ratio of a first repair material and a second repair material based on the detection signal, and generating a corresponding servo motor control command; driving the corresponding servo motor according to the servo motor control command, and simultaneously activating the compressed air supply; mixing the first repair material and the second repair material in an air jet mixer under the action of compressed air; and spraying the mixed material onto the gap in the carriage through a fan-shaped nozzle.

[0016] Compared with the prior art, the present invention has the following beneficial technical effects: This invention provides a train carriage leak repair spraying device, which achieves precise control and efficient processing of two-component leak repair materials through a specific structural design. The device features independently set first and second component supply structures, providing a basis for the storage and independent delivery of the two materials. Servo motors in each structure drive delivery pumps, enabling precise control of the output flow rate of their respective materials. The control unit includes a proportioning control module that receives detection signals regarding gap characteristics and dynamically adjusts the speed of the two servo motors accordingly, thereby changing the delivery ratio of the two materials to adapt the material output to different gap repair needs. The two materials are delivered to an air jet mixer, where they encounter compressed air. The compressed air forms a high-speed jet within the mixer, generating entrainment and shearing effects on the materials, promoting uniform mixing in a short time. This structural combination integrates precise electronic control of the material ratio with rapid forced mixing based on pneumatic principles.

[0017] This invention also provides a method for spraying a leak-sealing coating on train carriages, employing the train carriage leak-sealing coating device described above, defining a continuous operation process from information sensing to material forming. The method begins by receiving a detection signal characterizing the gap, and based on this signal, determines the output ratio of two leak-sealing materials, thereby generating a command to control a servo motor. When driving the servo motor according to the command, the compressed air supply is simultaneously activated, ensuring coordinated movement of the material flow and the kinetic airflow. In an air jet mixer, the two materials, supplied in proportion, are mixed under the action of compressed air. The mixed material is finally sprayed out through a fan-shaped nozzle, forming a coating covering the gap. This method uses gap information as a control input, linking material proportioning, synchronous delivery, and the mixing process, enabling each stage to operate collaboratively according to actual working conditions. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of a train carriage leak repair spraying device according to an embodiment of the present invention.

[0019] Figure 2 This is a schematic diagram of the air jet mixer structure in an embodiment of the present invention.

[0020] Figure 3 This is a schematic diagram of the nozzle structure in an embodiment of the present invention. In the figure, (a) is a front view of the nozzle and (b) is a side sectional view of the nozzle.

[0021] Figure 4 This is a flowchart of a method for repairing leaks in train carriages according to an embodiment of the present invention.

[0022] In the diagram, 1 is the frame; 2 is the storage tank; 3 is the heating belt; 4 is the servo motor; 5 is the conveying pump; 6 is the discharge pipe; 7 is the compressed air tank; 8 is the compressed air outlet; 9 is the air jet mixer; and 10 is the nozzle. Detailed Implementation

[0023] Crack repair in railway freight cars mainly relies on manual labor, which is inefficient and produces inconsistent quality. While existing automated equipment can move and position itself, it falls short in terms of precise proportioning and instantaneous uniform mixing of the core repair material. It often uses fixed proportions and simple mixing methods, making it difficult to guarantee repair quality.

[0024] Based on the above background, this invention proposes a leak-sealing spraying device and method for train carriages. The device achieves precise material metering through an independent dual-component supply structure and a servo motor, and dynamically adjusts the output ratio according to the gap characteristics using a proportioning control module. The material is uniformly mixed within seconds using compressed air in a dedicated air jet mixer, thus organically combining intelligent proportioning decision-making with efficient mixing execution to form a dedicated solution for leak-sealing processes. The method defines a coherent process from receiving gap signals, calculating proportions, synchronous driving, to mixing and spraying, ensuring that each step automatically coordinates according to the working conditions.

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

[0026] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0027] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0028] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a number" means two or more, unless otherwise explicitly specified.

[0029] Example 1: Reference Figure 1 The image shows a specific embodiment of the train carriage leak repair spraying device provided by the present invention, comprising: The material supply structure includes a first component supply structure and a second component supply structure. Both the first component supply structure and the second component supply structure include a storage tank 2. The storage tank 2 is equipped with a heating device. The storage tank 2 is connected to a delivery pump 5. The delivery pump 5 is connected to a servo motor 4. The storage tanks 2 of the first component supply structure and the second component supply structure are used to store two components of leak repair materials, respectively. The ejection structure includes an air jet mixer 9, which is provided with a first inlet, a second inlet, and a compressed air inlet. The first inlet is connected to a delivery pump 5 of a first component supply structure via a pipeline, the second inlet is connected to a delivery pump 5 of a second component supply structure via a pipeline, and the compressed air inlet is connected to a compressed air tank 7 via a pipeline. The other end of the air jet mixer 9 is connected to a nozzle 10. The control unit is electrically connected to the servo motor 4 of the material supply structure, the heating device, and the outlet valve of the compressed air tank 7, respectively. The control unit includes at least a proportioning control module. The ratio control module is used to receive detection signals that characterize the features of the gap to be repaired, and to determine the output ratio of the repair material according to the detection signals and control the rotation speed of the two servo motors 4.

[0030] In this specific embodiment, the material supply structure is the foundation of the device's material supply. Through symmetrically arranged first and second component supply structures, it achieves independent storage and delivery of the first and second patching materials. Each component supply structure is a functional unit: the storage tank stores the material; a heating device on the storage tank heats the material inside to maintain it within a suitable construction temperature range, ensuring material flowability; and the delivery pump, driven by a servo motor, pumps the material from the storage tank at a controllable flow rate. The two independent component supply structures provide the physical basis for subsequent precise ratio adjustment of the two-component materials.

[0031] The ejection structure is a key component in material mixing and molding. Its core is an air jet mixer, which has two feed inlets and one compressed air inlet. The two feed inlets are connected to the storage tanks of the two component supply structures via pipelines, thus receiving the two materials. The compressed air inlet is connected to a compressed air tank via pipeline to achieve hybrid mixing. The other end of the air jet mixer is connected to a nozzle, through which the mixed material is finally ejected. This structural design allows the two sealing materials and compressed air to converge within the air jet mixer.

[0032] The control unit serves as the central command for the device's intelligent and automated operation. It is electrically connected to the servo motors, heating devices, and compressed air tank outlet valves in the material supply structure, enabling coordinated control of these three components. Specifically, the control unit includes at least a proportioning control module. This module receives external detection signals characterizing the gaps to be repaired and, based on analysis and processing of these signals, determines the optimal output proportion of the first and second patching materials. Subsequently, the proportioning control module precisely controls the output flow of the respective drive pumps by adjusting the rotational speeds of the two servo motors, thereby physically achieving the determined material proportions.

[0033] In summary, this embodiment establishes a closed-loop automated spraying system through the organic integration and coordinated operation of the material supply structure, the spraying structure, and the control unit. The material supply structure is responsible for providing a controlled raw material flow, the spraying structure is responsible for completing the mixing and spraying of the material, and the control unit adjusts the proportion of the raw material flow in real time and with precision based on externally input working condition information (gap characteristics). These three components work together to achieve the core function of adaptive and precise proportioning spraying for different gap characteristics.

[0034] Example 2: In another specific embodiment of the train car leak repair spraying device provided by the present invention, based on the train car leak repair spraying device disclosed in Example 1, this embodiment further optimizes the design of each component and adds a number of auxiliary functional structures, so that the device has more complete operation performance, wider environmental adaptability and more convenient maintenance, and can better meet the actual needs of automatic reinforcement and leak repair of coal train car door gaps, effectively replace manual leak repair work, and achieve the technical effects of improving work efficiency, reducing the labor intensity of operators and improving the working environment, while further improving the quality and stability of leak repair construction.

[0035] The mixing control module is further configured to: use the gap size in the detection signal characterizing the gap to be repaired as the control basis, set a first threshold of 5cm for the gap size; when the detection signal indicates that the gap size is less than or equal to 5cm, control the two servo motors 4 to run at a first speed ratio; when the detection signal indicates that the gap size is greater than 5cm, control the two servo motors 4 to run at a second speed ratio. Simultaneously, the servo motors 4 send an opening signal to the outlet valve of the compressed air tank 7 to synchronously supply compressed air. Specifically, the control unit is electrically connected to the driver of the servo motors 4 and the solenoid valve on the compressed air pipeline. When the control unit receives the start spraying command, its internal program logic is configured to synchronously send an opening signal to the control circuit of the servo motor 4 driver and the solenoid valve, thereby achieving synchronous start of the servo motor 4 rotation and compressed air supply. This ensures that the two types of repair materials and compressed air can enter the air jet mixer 9 simultaneously, avoiding problems such as uneven mixing and material waste in the initial spraying stage due to asynchronous supply.

[0036] In this specific embodiment, the delivery pumps 5 used in the first component supply structure and the second component supply structure are metering pumps with the same displacement. Based on this setting, the speed ratio of the two servo motors 4 directly corresponds to the output volume ratio of the first repair material and the second repair material.

[0037] When the detection signal received by the proportioning control module indicates that the size of the gap to be repaired is less than or equal to 5 cm, the proportioning control module controls the two servo motors 4 to operate at a first speed ratio. The first speed ratio is the ratio of the speed of the servo motor 4 of the first component supply structure to the speed of the servo motor 4 of the second component supply structure, which is 1:1. Since the two delivery pumps 5 have the same displacement, this 1:1 speed ratio corresponds to a 1:1 output ratio of the first patching material to the second patching material. In this proportioning mode, precise filling of smaller gaps can be achieved.

[0038] When the detection signal received by the proportioning control module indicates that the size of the gap to be repaired is greater than 5cm, the proportioning control module controls the two servo motors 4 to operate at a second speed ratio. The second speed ratio is the ratio of the speed of the servo motor 4 of the first component supply structure to the speed of the servo motor 4 of the second component supply structure, which is 1:1.5. This 1:1.5 speed ratio corresponds to an output ratio of 1:1.5 for the first repair material and the second repair material, which is suitable for reinforcing and repairing larger gaps. The specific speed parameters are set as follows: When the two servo motors 4 operate at the first speed ratio, the speed of both servo motors 4 is 500 rpm, ensuring that the two types of sealing materials are output at the same flow rate, adapting to the sealing needs of smaller gaps, ensuring accurate use of sealing materials, and avoiding waste; when the two servo motors 4 operate at the second speed ratio, the speed of the servo motor 4 of the first component supply structure is 500 rpm, and the speed of the servo motor 4 of the second component supply structure is 750 rpm. By precisely controlling the speed difference between the two servo motors 4, a 1:1.5 ratio of the two sealing materials is achieved, adapting to the sealing needs of larger gaps, ensuring that the sealing materials have sufficient strength and adhesion, and guaranteeing the durability of the sealing effect.

[0039] The heating device includes a temperature sensor that monitors the internal temperature of the storage tank 2 and a heating actuator arranged on the outer wall of the storage tank 2. The heating actuator is specifically a heating band. A cover for adding material is also provided on top of the storage tank 2. It is also equipped with a conveying interface and a discharging interface. The conveying interface is used to connect to the conveying pump 5, and the discharging interface is used to connect to the conveying pipeline to achieve smooth delivery of the repair material. The control unit also includes a temperature control module, which can be integrated into the control unit of the entire device or set up separately. The temperature control module is electrically connected to the temperature sensor and the heating actuator and is configured to automatically regulate the temperature of the repair material inside the storage tank 2. The system sets a first preset temperature of 10℃ and a second preset temperature of 30℃. When the temperature of the repair material inside the storage tank 2 detected by the temperature sensor is lower than 10℃, the temperature control module controls the heating actuator to start, heating the repair material inside the storage tank 2. When the temperature of the repair material inside the storage tank 2 detected by the temperature sensor is higher than 30℃, the temperature control module controls the heating actuator to stop, thereby stabilizing the temperature of the repair material inside the storage tank 2 within the suitable construction temperature range of 10℃ to 30℃. This heating control structure can effectively cope with outdoor operation scenarios in extremely cold weather, avoiding problems such as decreased fluidity and solidification of the repair material due to excessively low temperature, ensuring smooth delivery and thorough mixing of the repair material, and guaranteeing the normal progress of the spraying operation.

[0040] The structure of the air jet mixer 9 is referenced. Figure 2As shown, the air jet mixer 9 includes a feeding structure, a premixing zone, and a mixing zone that are coaxially connected in sequence. The mixing zone, located away from the premixing zone, also has a spray zone for mounting nozzles 10. The feeding structure, premixing zone, mixing zone, and spray zone of the air jet mixer 9 are all coaxially arranged to ensure a smooth compressed air passage and to guarantee stable flow of the filling material and compressed air along the axial direction, thus improving the mixing effect. The first and second feed inlets are located on the side wall of the feeding structure, and are positioned opposite each other along the same diameter of the feeding structure. The compressed air inlet is located at the axial center of the end face of the feeding structure. A guide layer is provided inside the feeding structure, forming a certain accommodating space between the guide layer and the outer wall of the feeding structure. The first and second feed inlets are connected to the premixing zone through the guide layer. A compressed air guide channel is formed between the compressed air inlet and the guide layer, ensuring that compressed air can smoothly enter the premixing zone along the guide channel. The feed structure has a third diameter, the premixing zone has a first diameter, and the spraying zone has a second diameter, with the third diameter being larger than the first diameter and the second diameter being larger than the first diameter. The portion connecting the feed structure and the premixing zone contracts towards the axis to form a uniform frustum-shaped transition structure. A frustum-shaped structure is also used between the premixing zone and the spraying zone to achieve a uniform transition, allowing the sealant and compressed air to transition smoothly, reducing flow resistance and avoiding problems such as eddies and stagnation. The radial cross-sectional dimensions of the mixing zone are optimized to allow the two sealant materials and compressed air to undergo decompression, acceleration, and diffusion within the mixing zone, achieving sufficient shearing and agitation. This promotes uniform mixing of the two sealant materials in a very short time, accommodating the second-level reaction rate of the sealant materials, effectively ensuring the adhesion strength and density of the sealant after spraying, and improving the sealant quality.

[0041] The nozzle 10 refers to Figure 3The image shows a fan-shaped nozzle 10. Figure (a) is a front view of the nozzle 10, and Figure (b) is a side sectional view of the nozzle 10. The nozzle 10 is specifically designed for high-viscosity, fast-curing sealant materials. The nozzle 10 is connected to the spray end of the air jet mixer 9 via a quick-connect coupling, facilitating rapid disassembly and replacement of the nozzle 10, as well as subsequent maintenance and cleaning. The nozzle 10 has an internal spray channel with a large-diameter, short-path structure, effectively reducing the flow resistance of the sealant material and minimizing the risk of material retention inside the nozzle 10, thus reducing the probability of nozzle clogging. The spray end of the nozzle 10 has an arc-shaped guide surface, which guides the mixed sealant material to form a fan-shaped spray surface. The angle overlap of the fan-shaped spray surface is controlled at 25%~30%, ensuring uniform distribution of the sealant material within the spray area. This allows for precise coverage of the gaps in the vehicle compartment to be repaired, avoiding uneven spraying and missed areas. It also allows for precise control of the spray width and thickness, saving sealant material and further improving spray quality. The quick-release design of the quick-change connector serves as an auxiliary maintenance method. When the subsequent cleaning control module's purging and cleaning fails to be fully effective, or when extreme situations such as long-term downtime, abnormal material batches, or unexpected malfunctions cause the nozzle 10 to become clogged or worn, the quick-release design can be used to quickly disassemble the nozzle 10 for offline cleaning or replacement, ensuring the continuous operation capability of the device.

[0042] The control unit also includes a cleaning control module, which is configured to automatically purge and clean the air jet mixer 9 and the fan nozzle 10 after spraying, so as to prevent the repair material from remaining and solidifying in the internal channels of the air jet mixer 9 and the spraying channels of the fan nozzle 10, thus preventing clogging problems during the next spraying, extending the service life of the air jet mixer 9 and the fan nozzle 10, and ensuring the smoothness and quality of subsequent spraying operations. The specific control logic is as follows: After the spraying is completed, the cleaning control module first controls the delivery pump 5 to stop running, cuts off the supply of the first and second repair materials, and at the same time maintains the outlet valve of the compressed air tank 7 open for a preset time of 1 minute. The compressed air output from the compressed air tank 7 enters through the compressed air inlet of the air jet mixer 9, flows through the feeding structure, premixing zone, mixing zone and spraying zone of the air jet mixer 9 in sequence, and is then discharged through the spraying channel of the fan-shaped nozzle 10. During the flow process, the internal channels of the air jet mixer 9 and the spraying channel of the fan-shaped nozzle 10 are thoroughly purged, and the residual repair material is completely cleaned.

[0043] The train carriage leak repair spraying device of this embodiment also includes a frame 1. The frame 1 is used to integrate and install all components, making the device structure more compact and stronger, and facilitating on-site handling and operation. The frame 1 has internal space for the material supply structure and the spraying structure, which can provide a certain degree of protection for each component, preventing them from being affected by external collisions, dust contamination, etc., and extending the service life of the components. The bottom of the frame 1 is provided with a connecting plate, and the connecting plate is provided with a layered support frame. The storage tanks 2 of the first component supply structure and the second component supply structure are placed on the upper layer of the layered support frame, and the servo motor 4 and the delivery pump 5 are placed on the lower layer of the layered support frame. The layered arrangement can make reasonable use of the internal space of the frame 1, and at the same time make the arrangement of the storage tank 2, servo motor 4, and delivery pump 5 more regular, which facilitates the pipeline connection and wiring layout between the components, and also facilitates subsequent inspection and maintenance. The compressed air tank 7 is located between the two storage tanks 2 inside the frame 1. Since the compressed air tank 7 is relatively tall, no separate support frame is provided. The compressed air tank 7 is also equipped with necessary safety monitoring equipment such as a safety valve and a pressure gauge. The safety valve is used to prevent the internal pressure of the compressed air tank 7 from causing safety hazards due to excessive pressure. The pressure gauge is used to display the internal pressure value of the compressed air tank 7 in real time, so that the operator can monitor the operating status of the compressed air tank 7 in real time and ensure the stability and safety of the compressed air supply.

[0044] The train carriage leak repair spraying device of this embodiment achieves multiple functions through optimized design and coordinated operation of various components, possessing significant technical advantages: the layered arrangement of the material supply structure combined with the heating control function ensures both a stable supply of leak repair material and good fluidity of the material at a suitable temperature; the coordinated control of the proportioning control module with the servo motor 4 and compressed air tank 7 achieves precise proportioning and synchronous supply of leak repair material for different gap sizes, adapting to different working conditions; the optimized structure of the air jet mixer 9 combined with the dedicated design of the fan-shaped nozzle 10 achieves rapid and uniform mixing and precise spraying of the leak repair material, improving the quality of leak repair and material utilization; the cooperation of the cleaning control module and the quick-release structure enables automatic cleaning and convenient maintenance of the device, reducing maintenance costs and extending the service life of the device; the integrated design of the frame 1 makes the coordinated operation of various components more stable and facilitates on-site operation. In summary, the train car leak repair spraying device of this embodiment can fully meet the operational needs of automatic reinforcement and leak repair of coal train car door gaps, replace manual leak repair work, effectively improve operational efficiency, reduce the labor intensity of operators, improve the working environment, and at the same time improve the quality of leak repair and operational stability, thus possessing good practicality and promotional value.

[0045] Example 3: A specific embodiment of the present invention also provides a method for spraying to repair leaks in train carriages, referring to... Figure 4As shown, the train carriage leak repair spraying device provided in the above embodiment includes the following steps: Receive detection signals characterizing the features of the gap to be repaired; Based on the detection signal, the output ratio of the material is determined, and corresponding control commands for the servo motor 4 are generated; According to the control command, the corresponding servo motor 4 is driven, and the compressed air supply is turned on simultaneously, so that the repair material is mixed in the air jet mixer 9 under the action of compressed air. The mixed material is sprayed onto the gaps in the carriage through the fan-shaped nozzle 10.

[0046] The train carriage leak repair spraying method provided in this specific embodiment embodies a series of ordered steps from information input to completion of spraying using the device described in the above embodiments. The process begins with the step "receiving a detection signal characterizing the features of the gap to be repaired". This step is the initial action of the method, and its function is to acquire externally input parameter information reflecting the specific condition of the gap. This detection signal is the basis for the control unit to perform subsequent logical judgments and decisions.

[0047] Next, the step "determine the output ratio of the material based on the detection signal and generate corresponding servo motor control commands" is executed. This step is completed within the control unit. The control unit parses the received detection signal according to its internally preset control strategy. The control strategy maps parameters characterizing the gap features to specific control parameters, thereby directly outputting target speed values ​​for two servo motors that match the current gap features. Subsequently, the control unit generates corresponding drive signals based on the target speed values ​​and sends them to the servo motor drivers.

[0048] Based on the generated instructions, the execution step is "drive the corresponding servo motors according to the control instructions and simultaneously start the compressed air supply." This step is the physical execution stage of the control instructions. The control unit sends speed commands to the drivers of the two servo motors, enabling them to operate precisely, thereby outputting two types of patching materials in a predetermined ratio through the delivery pump. At the same time, the control unit sends an opening command to the valve controlling the compressed air passage. The starting of the servo motors and the opening of the compressed air supply are synchronized. This design ensures that the material and the kinetic airflow can reach the subsequent mixing station simultaneously, creating conditions for immediate mixing. Once the material and compressed air are ready, the step "mix the patching materials in the air jet mixer under the action of compressed air" is executed. The two patching materials are transported independently in the delivery pipeline until they enter the air jet mixer together. At this time, the high-speed flowing compressed air forms a specific flow field in the mixer, generating entrainment, shearing, and agitation effects on the two materials, causing them to achieve full and uniform physical mixing in a very short time, forming a homogeneous mixture to be sprayed.

[0049] Finally, the mixed material is sprayed through a fan-shaped nozzle onto the gaps in the carriage. The material, thoroughly mixed by the mixer, enters and flows through the fan-shaped nozzle under residual pressure and subsequent airflow. The unique internal flow channel and outlet geometry of the fan-shaped nozzle redistribute and guide the incoming mixed material flow, causing it to spread into a fan-shaped spray surface of uniform thickness and specific width upon exiting the nozzle. This spray surface ultimately covers and adheres to the surface of the carriage gaps, completing the repair work.

[0050] The above steps constitute a complete technical process from signal sensing, intelligent decision-making, precise proportioning and delivery, efficient mixing to final coating. Each step is interconnected, enabling coating operations tailored to the characteristics of gaps.

[0051] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A train carriage leak repair spraying device, characterized in that, include: The material supply structure includes a first component supply structure and a second component supply structure. Both the first component supply structure and the second component supply structure include a storage tank (2). The storage tank (2) is equipped with a heating device. The storage tank (2) is connected to a delivery pump (5). The delivery pump (5) is connected to a servo motor (4). The storage tanks (2) of the first component supply structure and the second component supply structure are used to store two types of leak repair materials, respectively. The ejection structure includes an air jet mixer (9), which is provided with a first inlet, a second inlet and a compressed air inlet. The first inlet is connected to the delivery pump (5) of the first component supply structure through a pipeline, the second inlet is connected to the delivery pump (5) of the second component supply structure through a pipeline, and the compressed air inlet is connected to a compressed air tank (7) through a pipeline. The other end of the air jet mixer (9) is connected to a nozzle (10). The control unit is electrically connected to the servo motor (4) of the material supply structure, the heating device and the outlet valve of the compressed air tank (7), respectively. The control unit includes at least a proportioning control module. The ratio control module is used to receive detection signals that characterize the features of the gap to be repaired, and to determine the output ratio of the repair material according to the detection signals and control the rotation speed of the two servo motors (4).

2. The train carriage leak repair spraying device according to claim 1, characterized in that, The proportioning control module is further configured as follows: When the detection signal indicates that the gap size is less than or equal to the first threshold, the two servo motors (4) are controlled to run at the first speed ratio; When the detection signal indicates that the gap size is greater than the first threshold, the two servo motors (4) are controlled to run at a second speed ratio; While the servo motor (4) is running, it sends an opening signal to the outlet valve of the compressed air tank (7) to supply compressed air synchronously.

3. The train carriage leak repair spraying device according to claim 2, characterized in that, The first speed ratio is the ratio of the speed of the servo motor (4) of the first component supply structure to the speed of the servo motor (4) of the second component supply structure, which is 1:

1. The second speed ratio is the ratio of the speed of the servo motor (4) of the first component supply structure to the speed of the servo motor (4) of the second component supply structure, which is 1:1.

5.

4. The train carriage leak repair spraying device according to claim 3, characterized in that, When the two servo motors (4) are running at the first speed ratio, the speed of both servo motors (4) is 500 rpm; When the two servo motors (4) are running at a second speed ratio, the servo motor (4) of the first component supply structure has a speed of 500 rpm and the servo motor (4) of the second component supply structure has a speed of 750 rpm.

5. The train carriage leak repair spraying device according to claim 1, characterized in that, The heating device includes a temperature sensor for monitoring the internal temperature of the storage tank (2) and a heating actuator arranged on the outer wall of the storage tank (2). The control unit further includes a temperature control module, which is electrically connected to the temperature sensor and the heating actuator and is configured to: When the temperature detected by the temperature sensor is lower than the first preset temperature, the heating actuator is activated. When the temperature detected by the temperature sensor is higher than the second preset temperature, the heating actuator is controlled to stop.

6. The train carriage leak repair spraying device according to claim 1, characterized in that, The air jet mixer (9) includes a feeding structure, a premixing zone and a mixing zone that are coaxially connected in sequence; The first and second feed inlets are located on the side wall of the feed structure, and the compressed air inlet is located at the center of the end face of the feed structure. The feeding structure is provided with a guide layer. The first feed port and the second feed port are connected to the premixing zone through the guide layer. A compressed air guide channel is formed between the compressed air inlet and the guide layer.

7. The train carriage leak repair spraying device according to claim 6, characterized in that, The nozzle (10) is a fan-shaped nozzle. The nozzle (10) is connected to the outlet end of the air jet mixer (9) through a quick-connect coupling. The nozzle (10) has an ejection channel inside and an arc-shaped guide surface at the ejection end.

8. The train carriage leak repair spraying device according to claim 1, characterized in that, The control unit also includes a cleaning control module, which is configured to stop the delivery pump (5) after the spraying is completed and keep the outlet valve of the compressed air tank (7) open for a preset time.

9. The train carriage leak repair spraying device according to claim 1, characterized in that, It also includes a frame (1), which has a material supply structure and a spraying structure accommodating space inside. The bottom of the frame (1) is provided with a connecting plate, and the connecting plate is provided with a layered support frame. The storage tanks (2) of the first component supply structure and the second component supply structure are placed on the upper layer of the layered support frame, and the servo motor (4) and the delivery pump (5) are placed on the lower layer of the layered support frame.

10. A method for spraying leak repair coating onto train carriages, employing the train carriage leak repair spraying device as described in any one of claims 1-9, characterized in that, Including the following steps: Receive detection signals characterizing the features of the gap to be repaired; Based on the detection signal, the output ratio of the material is determined, and corresponding servo motor (4) control commands are generated; Drive the corresponding servo motor (4) according to the control command, and simultaneously turn on the compressed air supply so that the repair material is mixed in the air jet mixer (9) under the action of compressed air; The mixed material is sprayed onto the gaps in the carriage through a fan-shaped nozzle (10).

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