Automatic barium sulfate spraying system for refining and casting

Abstract

The invention relates to the technical field of electrolytic refined copper, and particularly discloses a refined casting barium sulfate automatic spraying system which comprises an ejector pin detection knocking mechanism, a spraying mechanism, a copper mold smearing mechanism, a spraying detection mechanism and a controller. The ejector pin detecting and knocking mechanism, the spraying mechanism and the copper mold smearing mechanism are sequentially arranged in the disc rotating direction of the disc casting machine. The full-process automation of automatic thimble detection and knocking and barium sulfate spraying from detection and spraying to quality reinspection and remediation is achieved, and the three major problems that in traditional manual operation, quality is unstable, human factor fluctuation is eliminated through automation, and spraying consistency of all copper molds is ensured; the assembly line type automatic operation is obviously higher than the manual rhythm and is perfectly matched with the rhythm of a disc casting machine; potential safety hazards are large, workers are liberated from the severe environment with high temperature and dust, and intrinsic safety is achieved.

Description

Technical Field

[0001] This invention relates to the field of electrolytic copper refining technology, and in particular to an automatic spraying system for refining and casting barium sulfate. Background Technology

[0002] The raw material for electrolytically refined copper is the copper anode plate. To reduce energy consumption during the electrolytic refining process, the copper anode plate is required to have high precision and a good physical shape. Copper anode plates are usually cast by a disc casting machine, and the control of the casting process determines the precision and shape of the copper anode plate.

[0003] Barium sulfate plays a crucial role in the disc casting of anode plates as a release agent. It is sprayed onto the copper mold during anode plate casting, forming a protective film that serves a dual purpose: protecting the mold and improving the physical specifications of the anode plate. Specifically, barium sulfate is mixed with water to form an emulsion, which is then sprayed onto the copper mold during anode plate casting. This helps the hot anode plate to solidify and be demolded, ensuring smooth forming and demolding. The use of barium sulfate is essential for the disc casting process. It not only protects the mold and reduces mold wear but also improves the physical specifications of the anode plate. However, excessive use of barium sulfate can lead to high equipment failure rates, severe pollution at the work site, and may affect the efficiency of the electrolysis system and the quality of the anode plates. Therefore, rationally controlling the amount of barium sulfate used is of great significance for improving production efficiency and product quality.

[0004] Currently, in the Shuangshan refining workshop, the disc-cast anode plates are sprayed with barium sulfate slurry by a motor-driven mechanical rod. After ejecting the ingot, the ejector pins are difficult to fully return to their original position under their own weight, requiring manual tapping of the copper mold ejector pins. This method has the following problems: due to the special structure of the copper mold ears, such as... Figure 1 As shown, the barium sulfate spraying is uneven and cannot reach the ear of the mold, especially the inner wall of the ear. The coating quality on the copper mold surface is not high and manual intervention is required. Personnel are close to the moving equipment, and the on-site environment is hot and dusty, posing safety and occupational health hazards. The on-site personnel have a heavy workload and many tasks, and the level of automation is low. Summary of the Invention

[0005] Based on this, the purpose of this invention is to provide an automatic barium sulfate spraying system for refining and casting, which realizes real-time detection of copper mold pin height, automatic hammering, and automatic barium sulfate application, thereby improving the anode plate qualification rate, reducing labor intensity, and reducing on-site personnel.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This invention provides an automatic spraying system for refining and casting barium sulfate, used in a disc casting machine. It includes a pin detection and striking mechanism, a spraying mechanism, a copper mold coating mechanism, a spraying detection mechanism, and a controller. The pin detection and striking mechanism, the spraying mechanism, and the copper mold coating mechanism are arranged sequentially along the rotation direction of the disc in the disc casting machine. The ejector pin detection and tapping mechanism is used to detect whether the top surface of the ejector pin of each copper mold on the disc is flush with the bottom surface of the copper mold, and when the top surface of the ejector pin is not flush with the bottom surface of the copper mold, the ejector pin is tapped until it is detected that the top surface of the ejector pin is flush with the bottom surface of the copper mold. The spraying mechanism is used to spray barium sulfate onto the copper mold; The coating inspection agency is used to detect whether there are coating defects in the copper mold coating. If coating defects are found, a recoating signal is issued. The controller is used to control the copper mold coating mechanism to recoat the defective locations of the copper mold coating according to the recoating signal.

[0008] This invention achieves automatic detection and tapping of the ejector pin, and full automation of the barium sulfate spraying process from detection and spraying to quality re-inspection and remediation. This solves three major pain points of traditional manual operation: 1) Unstable quality: Automation eliminates fluctuations caused by human factors, ensuring the consistency of spraying for each copper mold; 2) Low production efficiency: The automated production line operation is significantly faster than manual operation, perfectly matching the rhythm of the disc casting machine; 3) Significant safety hazards: It liberates workers from the harsh environment of high temperature and dust, achieving inherent safety.

[0009] As a further improvement to the above-mentioned solution of the present invention, the ejector pin detection and striking mechanism includes a mounting frame, a mounting rod, a striking hammer, a guide sleeve, a cylinder, a connecting rope, and a detection component. The mounting frame is installed on the ground. One end of the mounting rod is installed on the mounting frame and the other end extends above the disc. The guide sleeve is vertically installed on the end of the mounting rod away from the mounting frame. One end of the striking hammer is slidably disposed inside the guide sleeve and the other end extends outside the guide sleeve. The cylinder body is installed on the mounting frame. One end of the connecting rope is connected to the piston rod end of the cylinder and the other end extends into the guide sleeve and is connected to the striking hammer. When the piston rod of the cylinder extends or retracts, the connecting rope pulls the striking hammer to slide up and down inside the guide sleeve to strike the ejector pin. The detection component is used to detect whether the top surface of the ejector pin of the copper mold is flush with the bottom surface of the copper mold. When it is detected that the top surface of the ejector pin is not flush with the bottom surface of the copper mold, the cylinder is triggered to drive the striking hammer to strike the ejector pin. The extension and retraction of the cylinder is converted into the up and down movement of the hammer. When the hammer descends, it strikes the ejector pin. The structure is simple and reliable, with sufficient power, and can generate instantaneous and precise impact force to ensure that the stuck ejector pin is struck into place in one go. It effectively replaces the blind and laborious hammering performed by manual tools, and ensures the efficiency and reliability of the pre-processing station.

[0010] As a further improvement to the above-mentioned solution of the present invention, the ejector pin detection and striking mechanism includes a mounting frame, a rotating rod, a striking hammer, a cylinder, and a detection component; the mounting frame is installed on the ground, one end of the rotating rod is rotatably mounted on the mounting frame and the other end extends above the disc, and the striking hammer is vertically mounted on the end of the rotating rod away from the mounting frame; the cylinder body is mounted on the mounting frame and the piston rod end is connected to the rotating rod, when the piston rod of the cylinder extends or shortens, the rotating rod rotates under the drive of the piston rod of the cylinder, so as to drive the striking hammer to strike the ejector pin; the detection component is used to detect whether the top surface of the ejector pin of the copper mold is flush with the bottom surface of the copper mold, and when it is detected that the top surface of the ejector pin is not flush with the bottom surface of the copper mold, it triggers the cylinder to rotate so as to drive the rotating rod to rotate and drive the striking hammer to strike the ejector pin. The mechanical linkage design of cylinder-rotating rod-hammer is simple, reliable and powerful, and can generate instantaneous and precise impact force to ensure that the stuck ejector pin is knocked into place in one go. It effectively replaces the blind and laborious knocking by manual tools and ensures the efficiency and reliability of the pre-processing station.

[0011] As a further improvement to the above-mentioned solution of the present invention, the detection component includes a depth camera and a processing module. The depth camera is used to capture images of the ejector pin area; the processing module is used to process the images of the ejector pin area and detect whether the top surface of the ejector pin is flush with the bottom surface of the copper mold. When it is detected that the top surface of the ejector pin is not flush with the bottom surface of the copper mold, a cylinder is triggered to drive a hammer to strike the ejector pin. The introduction of a depth camera for non-contact measurement achieves quantitative and high-precision detection. Compared with human observation or simple sensors, it can accurately determine height differences at the millimeter level, and the triggering of the striking action is objective and without delay. This provides an absolutely flat foundation for subsequent spraying, fundamentally avoiding uneven coating thickness or defects on the bottom surface of the ingot caused by ejector pin protrusion or depression.

[0012] As a further improvement to the above-mentioned solution of the present invention, the spraying mechanism includes a mold cavity spraying assembly and a copper mold ear spraying assembly. The copper mold ear spraying assembly includes a second mounting frame, a barium sulfate supply source, a high-pressure gas source, an atomized water vapor supply source, and a spraying component. The second mounting frame is installed on the ground, and a spraying hood that can cover the copper mold and maintain a predetermined distance from the copper mold is installed on the second mounting frame. The spraying component includes a spray gun, a first tube, and a second tube. The spray gun is located inside the spraying hood and is installed on the spraying component. On the coating hood, the outlet end of the spray gun is connected to a tube body one, and the other end of tube body one is connected to the middle of tube body two. At least one nozzle is installed at each end of tube body two. The barium sulfate supply, the high-pressure gas supply, and the atomized water vapor supply are all connected to the inlet end of the spray gun and respectively supply barium sulfate dry powder, high-pressure gas, and atomized water vapor to the spray gun. When the ear of the copper mold moves below tube body two, tube body two sprays barium sulfate dry powder, high-pressure gas, and / or atomized water vapor onto the ear of the copper mold through the two nozzles. A dedicated ear spraying assembly and spray hood are provided, enabling directional and enclosed spraying of the key parts (ears) of the copper mold. The spray hood effectively prevents barium sulfate dry powder from diffusing into the workshop air, ensuring environmental protection and worker health; at the same time, the concentrated spraying space improves powder utilization and reduces material costs.

[0013] As a further improvement to the above-mentioned solution of the present invention, two spraying parts are provided, each corresponding to one of the two ears of the copper mold, and the spray head is an electromagnetic spray head. By using two independent spraying parts corresponding to the two ears and employing electromagnetic spray heads, synchronous and independently controllable spraying is achieved. This ensures that the coating on the two ears is uniform and consistent. Furthermore, the electromagnetic spray head responds quickly and switches precisely, allowing for accurate control of the spraying cycle and avoiding material waste and contamination of non-target areas.

[0014] As a further improvement to the above-mentioned solution of the present invention, the barium sulfate supply source includes a dry powder mixing tank, a diaphragm pump, a conveying pipe, and a conveying pipe. The dry powder mixing tank stores barium sulfate dry powder. The discharge end of the diaphragm pump is connected to two spray guns through the conveying pipe, and a servo valve is installed on the conveying pipe. The feed end of the diaphragm pump is connected to the dry powder mixing tank through the conveying pipe. Through the feeding design of the dry powder mixing tank, diaphragm pump, and servo valve, continuous, stable, and accurate powder conveying is achieved. The mixing tank prevents powder caking, the diaphragm pump provides stable conveying power, and the servo valve achieves precise flow control. The three work together to ensure the uniformity of the spray coating thickness and the repeatability of the process.

[0015] As a further improvement to the above-mentioned solution of the present invention, the ear-shaped spraying mechanism further includes a water-vapor mixing gun, a third conveying pipe, and a fourth conveying pipe. The outlet of the water-vapor mixing gun is connected to the inlet of two spray guns, and the high-pressure air source is connected to the inlet of the water-vapor mixing gun through the third conveying pipe. The atomized water vapor supply is an ultrasonic atomizer, and the outlet of the ultrasonic atomizer is connected to the inlet of the water-vapor mixing gun through the fourth conveying pipe. A servo valve is installed on the third conveying pipe, and a servo valve is installed on the fourth conveying pipe. By introducing an independent water-vapor mixing gun and mixing the high-pressure air source with the atomized water vapor generated by the ultrasonic atomizer, an extremely fine and uniform mist can be produced. This mist, mixed with the release agent in the spray gun, can significantly improve the atomization effect and diffusion uniformity of the release agent, making it easier to adhere to the complex ear surface and form a uniform film, thus improving the spraying quality.

[0016] As a further improvement to the above-mentioned solution of the present invention, the spraying inspection mechanism includes a camera and a second processing module; the camera is used to capture images of the copper mold coating; the second processing module is used to process the images of the copper mold coating and detect whether there are spraying defects in the copper mold coating. If spraying defects are found, a recoating signal is issued. Setting up an automated spraying inspection mechanism upgrades quality inspection from manual sampling to fully automated full inspection. This ensures that the coating quality of each copper mold is objectively evaluated, eliminates missed inspections, and provides a decision-making basis for possible subsequent precise recoating, which is a key link in achieving closed-loop quality control.

[0017] As a further improvement to the above-mentioned solution of the present invention, the second processing module is configured to: preprocess the copper mold coating image using a CNN-based image dehazing algorithm to enhance image clarity; subsequently, identify and locate crack defects in the coating based on the YOLO target detection algorithm; when the width of the identified crack exceeds a preset width threshold, it is determined that there is a coating defect and a recoating signal is issued.

[0018] As a further improvement to the above-mentioned solution of the present invention, the copper mold coating mechanism includes a robotic arm, an applicator, a dry powder mixing tank II, a diaphragm pump II, a delivery pipe V, and a delivery pipe VI. The applicator is installed at the end of the robotic arm and is made of a porous adsorbent elastic material. The dry powder mixing tank II stores barium sulfate dry powder. The inlet end of the diaphragm pump II is connected to the dry powder mixing tank II via the delivery pipe V, and the outlet end of the diaphragm pump II is connected to the delivery pipe VI, on which a servo valve IV is installed. The end of the delivery pipe VI furthest from the diaphragm pump II extends into the applicator and is fixed to the robotic arm. The robotic arm and the servo valve IV are controlled by the controller. This automated recoating solution using a robotic arm and a porous adsorbent elastic applicator enables precise and flexible local repair of detected defects. The robotic arm is accurately positioned and can reach complex locations; the porous adsorbent material can carry an appropriate amount of barium sulfate dry powder and apply it with gentle pressure, avoiding damage to the surrounding intact coating. This achieves online and precise rework, transforming downgraded products that traditionally require overall repair or scrap into qualified products, significantly reducing the scrap rate.

[0019] Compared with the prior art, the present invention has the following beneficial effects: This invention achieves automatic detection and tapping of the ejector pin, and full automation of the barium sulfate spraying process from detection and spraying to quality re-inspection and remediation. This solves three major pain points of traditional manual operation: 1) Unstable quality: Automation eliminates fluctuations caused by human factors, ensuring the consistency of spraying for each copper mold; 2) Low production efficiency: The automated production line operation is significantly faster than manual operation, perfectly matching the rhythm of the disc casting machine; 3) Significant safety hazards: It liberates workers from the harsh environment of high temperature and dust, achieving inherent safety. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the copper mold structure; Figure 2 This is a schematic diagram of an automatic spraying system for refining and casting barium sulfate, provided in an embodiment of the present invention. Figure 3 This is a top view of an automatic spraying system for refining and casting barium sulfate, provided in an embodiment of the present invention. Figure 4 This is a schematic diagram of the structure of the ejector pin detection and striking mechanism in an automatic spraying system for refining and casting barium sulfate, provided by an embodiment of the present invention. Figure 5 This is a schematic diagram of the spraying mechanism in an automatic spraying system for refining and casting barium sulfate, provided by an embodiment of the present invention. Figure 6 This is a schematic diagram of the structure of a sprayed part in an automatic spraying system for refining and casting barium sulfate, provided by an embodiment of the present invention. Figure 7This is a schematic diagram of another structure of the pin detection and striking mechanism in an automatic spraying system for refining and casting barium sulfate, provided in an embodiment of the present invention.

[0021] Reference numerals in the attached drawings: 1. Ejector pin detection and striking mechanism; 101. Mounting bracket one; 102. Mounting rod; 103. Striking hammer; 104. Cylinder; 105. Depth camera; 106. Bracket; 107. Guide sleeve; 2. Spraying mechanism; 201. Mounting bracket two; 202. Spraying hood; 203. Spray gun; 204. Pipe body one; 205. Pipe body two; 206. Spray nozzle; 207. Dry powder mixing tank one; 208. Ultrasonic atomizer; 3. Copper mold coating mechanism; 301. Robotic arm; 302. Coating applicator; 4. Spraying detection mechanism; 401. Camera; 402. Mounting bracket three; 5. Disc; 501. Copper mold; 502. Ejector pin. Detailed Implementation

[0022] To facilitate understanding of the present invention, a more comprehensive description will be given below with reference to specific embodiments. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of the present invention.

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0024] Reference Figure 2 , Figure 3 This embodiment proposes an automatic spraying system for refining and casting barium sulfate for a disc casting machine. The system comprises, in sequence along the rotation direction of the disc in the disc casting machine: a pin detection and striking mechanism 1, a spraying mechanism 2, a spraying detection mechanism 4, and a copper mold coating mechanism 3. All of these mechanisms are coordinated and controlled by a controller (e.g., an industrial PLC or industrial computer).

[0025] The disc 5 of the disc casting machine has multiple copper molds 501 evenly distributed on it to receive molten metal. Each copper mold 501 has an ejector pin hole at its bottom, through which an ejector pin 502 is movably inserted to eject the formed ingot. Ideally, the top surface of the ejector pin is flush with the inner bottom surface of the copper mold to ensure the smoothness of subsequent spraying and casting.

[0026] like Figure 4 As shown, the pin detection striking mechanism includes a mounting bracket 101, a mounting rod 102, a guide sleeve 107, a striking hammer 103, a cylinder 104, a connecting rope, and a detection component.

[0027] Mounting bracket 101 is fixed to the ground base. One end of mounting rod 102 is mounted on mounting bracket 101, and the other end extends horizontally above disk 5. Guide sleeve 107 is vertically mounted on the end of mounting rod 102 away from mounting bracket 101. One end of hammer 103 is slidably disposed inside guide sleeve, and the other end extends outside guide sleeve. Cylinder body of cylinder 104 is mounted on mounting rod 102. One end of connecting rope is connected to piston rod end of cylinder 104, and the other end extends into guide sleeve 107 and is connected to hammer 103. When piston rod of cylinder 104 extends or retracts, hammer 103 is pulled up and down inside guide sleeve 107 by connecting rope to strike pin 502.

[0028] The inspection component includes a depth camera 105 and a processing module (integrated into the controller). A bracket 106 is fixed on the mounting rod 102 near the striking hammer 103. The depth camera 105 is mounted on the bottom of the bracket 106, with its lens pointing vertically downwards towards the ejector pin 502 area of ​​the copper mold 501.

[0029] The working process of the impact detection mechanism 1 is as follows: During operation, the disc 5 rotates intermittently. When a copper mold to be cast reaches the casting station, the disc pauses (generally for about 22 seconds). After the casting of the copper mold is completed, the disc continues to rotate. When the disc 5 rotates, carrying a copper mold 501, to the ejector pin 502 inspection station, the depth camera 105 captures a depth image of the area of ​​the copper mold 501 and ejector pin 502 and sends it to the processing module one. The processing module one processes the image: first, it identifies and segments the top surface area of ​​the ejector pin 502 and the bottom surface area of ​​the copper mold 501, and then calculates the average height difference between the two areas. If the absolute value of the height difference exceeds a preset threshold, it is determined to be uneven, and the processing module one immediately sends a pulse signal to the cylinder 104. The cylinder 104 actuates once, driving the hammer 103 to quickly strike the head of the ejector pin 502 once. After the strike, the inspection piece is inspected again. During the disc pause (approximately 22 seconds), this inspection-tapping cycle continues until the height difference is detected to be within the allowable range. Then, the disc 5 continues to rotate, conveying the copper mold 501 to the next station. This process ensures that the ejector pin 502 of each copper mold 501 is in the correct position before spraying.

[0030] The spraying mechanism 2 is responsible for spraying barium sulfate onto the inner surface of the copper mold 501 (hereinafter referred to as the mold cavity) and its two ears. The spraying mechanism 2 mainly includes a mold cavity spraying assembly (not shown separately in the figure, using existing barium sulfate spraying equipment, which will not be described in detail here) and a copper mold ear spraying assembly.

[0031] like Figure 5As shown, the copper mold ear spraying assembly includes mounting bracket 201, spraying hood 202, barium sulfate supply source, high-pressure gas source, atomized water vapor supply source, and two sets of symmetrically arranged spraying parts.

[0032] Mounting bracket 201 is fixed to the ground. A spray hood 202 is mounted on mounting bracket 201, its shape covering the entire copper mold 501 to prevent dust escape. It maintains a predetermined distance from the copper mold 501 to avoid obstructing its rotation. The barium sulfate supply includes a dry powder mixing tank 207, a diaphragm pump, a delivery pipe, and a delivery pipe. The dry powder mixing tank 207 has a built-in agitator that continuously stirs at low speed to prevent the barium sulfate powder from caking. The diaphragm pump draws powder from the dry powder mixing tank 207 through delivery pipe 2 and pumps it out through delivery pipe 1. The high-pressure air source is the factory's air source, providing dry and stable compressed air. The atomized water vapor supply uses an ultrasonic atomizer 208, which can atomize water or specific liquid media into micron-sized water vapor.

[0033] like Figure 6 As shown, the sprayed part includes a spray gun 203, a first tube 204, and a second tube 205. The spray gun 203 is fixed inside the spray hood 202, and its feed end is connected to the first conveying tube (dry powder) and the output end of the water-air mixing gun. The input end of the water-air mixing gun is connected to a high-pressure air source through a third conveying tube and to an ultrasonic atomizer through a fourth conveying tube. Servo valves one, two, and three are respectively installed on the first, third, and fourth conveying tubes for precise control of the flow rate and switching sequence of each medium. The discharge end of the spray gun 203 is connected to the first tube 204, and the end of the first tube 204 is connected to the middle of a horizontally placed second tube 205. The length direction of the second tube 205 is consistent with the extension direction of the ear of the copper mold 501, and two electromagnetic nozzles 206 are installed at each end. Of the two nozzles 206 at each end, one nozzle 206 faces the bottom surface of the ear, and the other nozzle 206 faces the inner wall surface of the ear.

[0034] The workflow for spraying the copper mold ear assembly is as follows: When the disc pauses (generally for about 22 seconds), one of the copper molds 501 moves into the spray hood 202. The two ears of the copper mold 501 are located directly below the pipes 205 of the two sprayers. The controller controls the valves according to the preset program: First, it controls the two nozzles 206 facing the bottom of the ears to open, and controls the servo valve 2 to open. High-pressure gas is sprayed into the two ears of the copper mold 501 through the delivery pipe 2, water-air mixing gun, spray gun 203, spray pipe, and nozzle 206, achieving targeted air blowing cleaning of the two ears of the copper mold 501 to remove residual powder. If there is still powder adhering to the ears, the servo valve 3 and the ultrasonic atomizer can be opened to use mist to wet and wash away stubborn residue. Then, servo valve three is closed for separate air blowing cleaning, drying the pipeline and ear area. Next, servo valve one, servo valve three, the diaphragm pump, and the other two nozzles 206 are opened. The atomized water vapor generated by the ultrasonic atomizer 208 and the high-pressure air are mixed in the water-vapor mixing gun to form high-pressure water vapor. This high-pressure water vapor is then delivered to the powder coating gun 203, where it mixes with barium sulfate dry powder and is delivered to the four nozzles 206 to perform fine mist spraying on the inner wall and bottom surface of the ear area of ​​the copper mold 501. After spraying, servo valve one and servo valve three are closed first, with the air blowing action delayed to prevent nozzle 206 from clogging. Finally, servo valve two and the four nozzles 206 are closed, completing the fine spraying of the ear area of ​​the copper mold 501. The entire ear spraying process is completed during the disc pause (approximately 22 seconds).

[0035] The spraying inspection mechanism 4 is located after the spraying mechanism 2 and includes a high-resolution industrial camera 401 and a processing module 2 (integrated into the controller or a standalone industrial computer).

[0036] An industrial camera 401 is positioned above the disc 5 and mounted on the spray hood 202 via a mounting bracket 3 402, its field of view covering the entire inner cavity of the copper mold 501. When the copper mold 501, after spraying, moves to a position below the industrial camera 401, the industrial camera 401 captures high-resolution color or grayscale images of the coating on the copper mold 501.

[0037] Processing module two runs the image processing algorithm, and its process is as follows: S1: Image Preprocessing. First, the input copper mold coating image is subjected to image dehazing enhancement processing based on CNN (Convolutional Neural Network) to eliminate the interference of water vapor and dust that may be caused by the workshop environment, and significantly improve the image contrast and detail clarity.

[0038] S2: Defect Detection and Recognition. The pre-processed image is input into a pre-trained YOLO object detection neural network model. This model can quickly identify and locate cracks in the coating and mark them with bounding boxes.

[0039] S3: Analysis and Decision. For the identified crack defects, processing module 2 immediately generates a recoating signal containing the crack location coordinates (relative to the copper mold reference point) and sends it to the controller.

[0040] The copper mold coating mechanism 3 is used to receive the recoating signal, and it includes a robotic arm 301, a coater 302, and a dry powder supply for recoating.

[0041] The applicator 302 is mounted on the end flange of the robotic arm 301 via a quick-change device. It is block-shaped or brush-head-shaped and made of a porous adsorbent elastic material, such as polyurethane (PU) sponge with high porosity, wear resistance, and resistance to weak acids and alkalis, or foamed silicone rubber with better high-temperature resistance. The material has a large number of interconnected micropores inside, which can adsorb and retain the barium sulfate dry powder to be applied.

[0042] The dry powder supply system includes a dry powder mixing tank (II), a diaphragm pump (II), a delivery pipe (V), and a delivery pipe (VI). The dry powder mixing tank (II) stores barium sulfate dry powder and is kept uniform by a stirrer. The diaphragm pump (II) draws dry powder from the tank through delivery pipe (V) and pumps it out through delivery pipe (V) (VI). The end of delivery pipe (V) (VI) is fixed to a robotic arm (301) and connected to the interior of an applicator (302), thereby delivering the barium sulfate dry powder to the applicator (302). A servo valve (IV) is installed on delivery pipe (V) (VI) to control the flow of barium sulfate dry powder.

[0043] The working process of the copper mold coating mechanism 3 is as follows: After the controller forwards the recoating signal from the spraying inspection mechanism 4, the robotic arm 301 plans its movement path based on the position coordinates in the signal, driving the applicator 302, which adsorbs barium sulfate dry powder, to move into the copper mold 501. Then, the robotic arm 301 presses the applicator 302 against the recoating area with appropriate force and angle, and moves the applicator 302 along the predetermined path to perform the recoating. At the same time, the controller can instruct the servo valve to open for four seconds to replenish the applicator 302 with fresh barium sulfate dry powder, ensuring the recoating effect. After the recoating is completed, the robotic arm 301 resets, ready for the next task. The entire spraying inspection and copper mold coating process is completed during the disc pause (approximately 22 seconds).

[0044] In another embodiment, such as Figure 7 As shown, the ejector pin detection and striking mechanism adopts the following structural design: The impact-detecting mechanism includes a mounting bracket 101, a rotating rod 102, an impact hammer 103, a cylinder 104, and a detection component. The mounting bracket 101 is fixed to a ground base. One end of the rotating rod 102 is rotatably mounted on the mounting bracket 101 via a bearing seat, while the other end extends horizontally above the disc 5. The impact hammer 103 is vertically fixed below the end of the rotating rod 102 furthest from the mounting bracket 101. The cylinder body of the cylinder 104 is hinged to the mounting bracket 101, and the end of its piston rod is hinged to the rotating rod 102. When the piston rod of the cylinder 104 extends or retracts, it drives the rotating rod 102 to reciprocate within a certain angle around its fulcrum, thereby causing the impact hammer 103 to perform lifting and striking actions.

[0045] The inspection component includes a depth camera and a processing module (integrated into the controller). A bracket is fixed to the ground, and the depth camera is mounted at the bottom of the bracket with its lens pointing vertically downwards towards the ejector pin 502 area of ​​the copper mold 501.

[0046] The working process of the impact detection mechanism 1 is as follows: During operation, the disc 5 rotates intermittently. When a copper mold to be cast reaches the casting station, the disc 5 pauses (generally for about 22 seconds). After the casting of the copper mold is completed, the disc continues to rotate. When the disc 5 rotates, carrying a copper mold 501, and reaches the ejector pin 502 inspection station, the disc 5 pauses. At this time, the depth camera captures a depth image of the area of ​​the ejector pin 502 and sends it to processing module one. Processing module one processes the image: first, it identifies and segments the top surface area of ​​the ejector pin 502 and the bottom surface area of ​​the copper mold 501, and then calculates the average height difference between the two areas. If the absolute value of the height difference exceeds a preset threshold, it is determined to be uneven, and processing module one immediately sends a pulse signal to cylinder 104. Cylinder 104 actuates once, driving the hammer 103 to quickly strike the head of the ejector pin 502 once. After the strike, the inspection piece is inspected again. During the disc pause (approximately 22 seconds), this inspection-tapping cycle continues until the height difference is detected to be within the allowable range. Then, the disc 5 continues to rotate, conveying the copper mold 501 to the next station. This process ensures that the ejector pin 502 of each copper mold 501 is in the correct position before spraying.

[0047] In summary, the overall workflow of the automatic spraying system for refining and casting barium sulfate in this embodiment is as follows: 1. The casting machine 5 is started, and the copper mold 501 rotates with the stepping of the disc 5.

[0048] 2. After passing through the ejector pin detection and tapping mechanism 1, ensure that the top surface of all ejector pins 502 is flush with the bottom of the mold.

[0049] 3. Entering the spraying mechanism 2, the mold cavity and ear are uniformly sprayed with a barium sulfate coating.

[0050] 4. The coating enters the spraying inspection unit 4, where camera 401 takes pictures to determine the coating quality. If there are no defects, the copper mold 501 flows directly to the casting station; if defects are found, a recoating signal is generated.

[0051] 5. The controller directs the robotic arm 301 of the copper mold coating mechanism 3 to precisely coat the defective areas.

[0052] The aforementioned automated integrated system has enabled the unmanned and intelligent operation of the barium sulfate spraying process, completely solving the problems of unstable quality, low efficiency, and dust hazards associated with traditional manual operations.

[0053] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0054] It should be noted that when a component is said to be "installed on" another component, it can be directly on the other component or it may be in a component that is centered on it. When a component is said to be "set on" another component, it can be directly set on the other component or it may also be in a component that is centered on it. When a component is said to be "fixed to" another component, it can be directly fixed to the other component or it may also be in a component that is centered on it.

[0055] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "or / and" as used herein includes any and all combinations of one or more of the associated listed items.

[0056] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0057] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. An automatic spraying system for refining and casting barium sulfate, used in a disc casting machine, characterized in that, It includes a pin detection and striking mechanism, a spraying mechanism, a copper mold coating mechanism, a spraying detection mechanism, and a controller. The pin detection and striking mechanism, the spraying mechanism, and the copper mold coating mechanism are arranged sequentially along the rotation direction of the disc of the disc casting machine; wherein: The ejector pin detection and tapping mechanism is used to detect whether the top surface of the ejector pin of each copper mold on the disc is flush with the bottom surface of the copper mold, and when the top surface of the ejector pin is not flush with the bottom surface of the copper mold, the ejector pin is tapped until it is detected that the top surface of the ejector pin is flush with the bottom surface of the copper mold. The spraying mechanism is used to spray barium sulfate onto the copper mold; The coating inspection agency is used to detect whether there are coating defects in the copper mold coating. If coating defects are found, a recoating signal is issued. The controller is used to control the copper mold coating mechanism to recoat the defective locations of the copper mold coating according to the recoating signal.

2. The automatic spraying system for refining and casting barium sulfate according to claim 1, characterized in that, The ejector pin detection and striking mechanism includes a mounting frame, a mounting rod, a striking hammer, a guide sleeve, a cylinder, a connecting rope, and a detection component. The mounting frame is installed on the ground. One end of the mounting rod is mounted on the mounting frame, and the other end extends above the disc. The guide sleeve is vertically mounted on the end of the mounting rod away from the mounting frame. One end of the striking hammer is slidably disposed inside the guide sleeve, and the other end extends outside the guide sleeve. The cylinder body is mounted on the mounting frame. One end of the connecting rope is connected to the piston rod end of the cylinder, and the other end extends into the guide sleeve and connects to the striking hammer. When the piston rod of the cylinder extends or retracts, the connecting rope pulls the striking hammer to slide up and down inside the guide sleeve to strike the ejector pin. The detection component is used to detect whether the top surface of the ejector pin of the copper mold is flush with the bottom surface of the copper mold. If it detects that the top surface of the ejector pin is not flush with the bottom surface of the copper mold, it triggers the cylinder to drive the striking hammer to strike the ejector pin.

3. The automatic spraying system for refining and casting barium sulfate according to claim 1, characterized in that, The ejector pin detection and striking mechanism includes a mounting frame, a rotating rod, a striking hammer, a cylinder, and a detection component. The mounting frame is installed on the ground. One end of the rotating rod is rotatably mounted on the mounting frame, and the other end extends above the disc. The striking hammer is vertically mounted on the end of the rotating rod away from the mounting frame. The cylinder body is mounted on the mounting frame, and the end of its piston rod is connected to the rotating rod. When the piston rod of the cylinder extends or retracts, the rotating rod rotates under the drive of the piston rod, thereby driving the striking hammer to strike the ejector pin. The detection component is used to detect whether the top surface of the ejector pin of the copper mold is flush with the bottom surface of the copper mold. If it detects that the top surface of the ejector pin is not flush with the bottom surface of the copper mold, it triggers the cylinder to rotate, thereby driving the rotating rod to rotate and driving the striking hammer to strike the ejector pin.

4. The automatic spraying system for refining and casting barium sulfate according to claim 2 or 3, characterized in that, The detection component includes a depth camera and a processing module. The depth camera is used to capture images of the ejector pin area. The processing module is used to process the images of the ejector pin area and detect whether the top surface of the ejector pin is flush with the bottom surface of the copper mold. When it is detected that the top surface of the ejector pin is not flush with the bottom surface of the copper mold, the cylinder is triggered to drive the hammer to strike the ejector pin.

5. The automatic spraying system for refining and casting barium sulfate according to claim 1, characterized in that, The spraying mechanism includes a mold cavity spraying assembly and a copper mold ear spraying assembly. The copper mold ear spraying assembly includes a second mounting frame, a barium sulfate supply source, a high-pressure gas source, an atomized water vapor supply source, and a spraying component. The second mounting frame is installed on the ground, and a spraying hood is installed on the second mounting frame to cover the copper mold and maintain a predetermined distance from the copper mold. The spraying component includes a spray gun, a first tube, and a second tube. The spray gun is located inside the spraying hood and installed on the spraying hood. The discharge end of the spray gun is connected to the first tube, and the other end of the first tube is connected to the middle of the second tube. At least one nozzle is provided at both ends of the second tube. The barium sulfate supply source, the high-pressure gas source, and the atomized water vapor supply source are all connected to the feed end of the spray gun and respectively supply barium sulfate dry powder, high-pressure gas, and atomized water vapor to the spray gun. When the ear of the copper mold moves to below the second tube, the second tube sprays barium sulfate dry powder, high-pressure gas, and / or atomized water vapor onto the ear of the copper mold through the two nozzles.

6. The automatic spraying system for refining and casting barium sulfate according to claim 4, characterized in that, Two spraying parts are provided, each corresponding to one of the two ears of the copper mold, and the spray nozzle is an electromagnetic spray nozzle.

7. The automatic spraying system for refining and casting barium sulfate according to claim 5, characterized in that, The barium sulfate supply includes a dry powder mixing tank, a diaphragm pump, a conveying pipe, and a conveying pipe. The dry powder mixing tank contains barium sulfate dry powder. The discharge end of the diaphragm pump is connected to two spray guns through the conveying pipe, and a servo valve is installed on the conveying pipe. The feed end of the diaphragm pump is connected to the dry powder mixing tank through the conveying pipe.

8. The automatic spraying system for refining and casting barium sulfate according to claim 5, characterized in that, The ear-shaped spraying mechanism also includes a water-vapor mixing gun, a third conveying pipe, and a fourth conveying pipe; the outlet of the water-vapor mixing gun is connected to the inlet of two spray guns, and the high-pressure air source is connected to the inlet of the water-vapor mixing gun through the third conveying pipe; the atomizing water-vapor supply source adopts an ultrasonic atomizer, and the outlet of the ultrasonic atomizer is connected to the inlet of the water-vapor mixing gun through the fourth conveying pipe; a servo valve is installed on the third conveying pipe, and a servo valve is installed on the fourth conveying pipe.

9. The automatic spraying system for refining and casting barium sulfate according to claim 1, characterized in that, The coating inspection mechanism includes a camera and a second processing module. The camera is used to capture images of the copper mold coating. The second processing module is used to process the images of the copper mold coating and detect whether there are coating defects. If coating defects are found, a recoating signal is issued. The second processing module is configured to: preprocess the images of the copper mold coating using a CNN-based image dehazing algorithm to enhance image clarity; subsequently, identify and locate crack defects in the coating using a YOLO target detection algorithm; when the width of the identified crack exceeds a preset width threshold, it is determined that there is a coating defect and a recoating signal is issued.

10. The automatic spraying system for refining and casting barium sulfate according to claim 1, characterized in that, The copper mold coating mechanism includes a robotic arm, an applicator, a dry powder mixing tank 2, a diaphragm pump 2, a delivery pipe 5, and a delivery pipe 6. The applicator is installed at the end of the robotic arm and is made of a porous, absorbent, elastic material. The dry powder mixing tank 2 stores barium sulfate dry powder. The inlet end of the diaphragm pump 2 is connected to the dry powder mixing tank 2 through the delivery pipe 5, and the outlet end of the diaphragm pump 2 is connected to the delivery pipe 6. A servo valve 4 is installed on the delivery pipe 6. The end of the delivery pipe 6 away from the diaphragm pump 2 extends into the applicator and is fixed to the robotic arm. The robotic arm and the servo valve 4 are controlled by the controller.

Images