Plasma spraying apparatus and spraying method for nickel mesh electrodes

Abstract

The application is suitable for the nickel mesh electrode spraying technical field, and provides a nickel mesh electrode plasma spraying device, which comprises a positioning planning frame, the positioning planning frame comprises a plasma spraying gun, a positioning frame and an electric push rod one, the positioning frame comprises a rear drive positioning frame and two front drive positioning frames, the rear drive positioning frame is slidably assembled on the positioning frame, the rear drive positioning frame is used for positioning the nickel mesh row by row, and a row distance is formed between the rear drive positioning frame and the front drive positioning frames, the row distance forms a spraying path in the forward movement of the plasma spraying gun; the rationality and uniformity of the nickel mesh spraying are improved, and the situation that spraying is overlapped or gaps appear due to missing spraying is avoided; a spraying method of the nickel mesh electrode plasma spraying device comprises nickel mesh pretreatment and positioning tensioning, wrinkle detection and flattening treatment, spraying path width self-adaptive adjustment, row distance setting and spraying path planning, row-by-row spraying and batch positioning point adjustment, coating post-treatment and unloading, and system parameter self-learning and optimization.

Description

Technical Field

[0001] This invention relates to the field of nickel mesh electrode spraying technology, and more specifically, to a plasma spraying apparatus and method for nickel mesh electrodes. Background Technology

[0002] Nickel mesh electrodes are a key component in alkaline water electrolysis for hydrogen production, and the performance of their surface catalytic coating directly determines the hydrogen production efficiency and operational life of the electrolyzer. To enhance the catalytic activity of nickel mesh electrodes, plasma spraying technology is widely used in industry. This technology utilizes a high-temperature plasma flame generated by a non-transfer plasma arc as a heat source to heat nickel-based alloy powder (such as nickel-aluminum, nickel-molybdenum-aluminum, etc.) to a molten or semi-molten state, and then sprays it at high speed onto the surface of the nickel mesh substrate to form a robust catalytic coating. Compared to traditional spraying methods such as electrodeposition and high-temperature sintering, plasma spraying offers advantages such as high coating bonding strength, the ability to prepare multi-element alloy coatings, and high production efficiency, and has become the mainstream manufacturing process for nickel mesh electrodes in large-scale alkaline electrolyzers.

[0003] Currently, various plasma spraying devices and related equipment for nickel mesh electrodes have been disclosed or put into use. For example, Zhengzhou Lijia Thermal Spraying Machinery Co., Ltd. disclosed the DP02 and DP03 green hydrogen electrode spraying production lines, which adopt an automatic conveying sandblasting system, an automatic exchange dual-platform system, and a four-axis robotic arm for automatic spraying, enabling automated spraying of nickel mesh electrodes. Guangzhou Sanxin Metal Technology Co., Ltd. proposed the SX-2550PA fully automatic nickel mesh spraying production line platform, equipped with two sets of SX-80 plasma spraying equipment, multiple robotic arms, and an automatic sandblasting system, completing the sandblasting and spraying processes in the same spray booth. In addition, patent document CN119303760A discloses a spraying device for surface modification treatment of electrolytic cell electrodes. This device integrates multiple functions such as conveying and feeding, positioning and clamping, sliding spraying, and rotating roller coating, aiming to solve the problems of single spraying methods and inconvenient loading and unloading during nickel mesh electrode modification spraying. However, the above-mentioned existing devices still have certain technical limitations in practical applications.

[0004] Existing plasma spraying devices for nickel mesh electrodes often suffer from limitations due to the limited spray width of the plasma spray gun, making it difficult to cover the entire nickel mesh surface in one go. Therefore, they commonly employ a reciprocating scanning spraying method along a preset path, spraying the positioned and clamped nickel mesh row by row and column by column. However, this row-scanning spraying method is prone to problems such as coating overlap or missed gaps at the boundaries between adjacent sprayed rows due to improper path spacing control. If the spacing between the spraying paths of adjacent rows is too small, the coating thickness at the boundary is significantly higher than in the central area, forming local bulges; if the spacing is too large, the coating coverage at the boundary is insufficient, or even uncoated gaps appear, resulting in uneven coating thickness across the entire nickel mesh surface. This uneven coating thickness not only affects the consistency of the electrode's catalytic activity but also damages the integrity of the porous structure during subsequent alkaline activation treatment due to uneven aluminum dissolution, ultimately reducing the overall hydrogen production efficiency and operational stability of the electrolyzer. For example, the plasma spraying device used in the patent application No. 202411029412.8, which describes a multi-alloy electrode for alkaline water electrolysis to produce hydrogen and its spraying method, also requires the previous electrode to be sprayed before a new electrode can be placed. Furthermore, during the spraying process, the spray gun needs to scan the nickel mesh surface row by row, which carries the risk of coating overlap or missed areas at the intersections of the scan rows, affecting processing efficiency and coating quality consistency. Similarly, although Zhengzhou Lijia's DP02 production line uses a four-axis robot to plan the spraying path in a graphic mode for automatic spraying, the spray gun also faces the problem of row spacing control accuracy during the reciprocating scanning process. The error in the path spacing programmed by the robot is difficult to completely eliminate, and the coating uniformity still needs improvement. Therefore, how to solve the problem of uneven coating thickness caused by the row scanning spraying method in existing nickel mesh electrode plasma spraying devices is a technical bottleneck that urgently needs to be overcome. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies: existing plasma spraying devices for nickel mesh electrodes cannot cover the entire nickel mesh with the plasma spraying gun. The plasma spraying gun needs to spray the already positioned nickel mesh row by row, which easily leads to overlapping spraying or gaps at the junction of each row. The invention proposes a plasma spraying device and spraying method for nickel mesh electrodes.

[0006] The specific technical solution is as follows: a plasma spraying device for nickel mesh electrodes, including a positioning frame and a positioning frame for positioning the nickel mesh. The positioning frame is used for positioning the nickel mesh after it has been stretched and flattened. The positioning frame is slidably mounted on the positioning frame. The positioning frame includes a plasma spray gun, a positioning frame, and an electric push rod. The positioning frame is slidably mounted on the positioning frame. Two electric push rods are provided and fixed on both sides of the positioning frame respectively, and are assembled with the positioning frame. The extension and retraction of the electric push rods can drive the positioning frame to reciprocate along the positioning frame. The plasma spray gun is used to plasma spray nickel mesh; the positioning frame includes a rear positioning frame and two front positioning frames, which are symmetrically distributed and slidably mounted on the rear positioning frame; the plasma spray gun is mounted on the front positioning frame and can move synchronously with the front positioning frame on the rear positioning frame; the rear positioning frame is slidably mounted on the positioning frame and is used to position the nickel mesh row by row, forming a row spacing with the front positioning frame, which forms the spraying path as the plasma spray gun moves forward.

[0007] In one technical solution, the rear drive positioning frame includes an outer guide frame and two positioning plate assemblies disposed inside the outer guide frame; the two positioning plate assemblies are symmetrically distributed inside the outer guide frame; the outer guide frame includes an outer guide frame body, which is rectangular in shape, and a guide groove is provided on the upper and lower sides of the outer guide frame body; the front drive positioning frame is slidably mounted on the guide groove, and its sliding position on the guide groove is controlled by an electric push rod five mounted inside the guide groove; a guide hole is provided on each side of the outer guide frame body, and the outer guide frame body is slidably mounted on the positioning frame through the guide hole.

[0008] In one technical solution, the positioning plate assembly includes multiple unit positioning plates, which are distributed on one side inside the outer guide frame and arranged in a straight line array. Each unit positioning plate includes a support plate, an electric push rod, a guide rail, and a pressing plate. One end of the electric push rod is fixed to the support plate, and the other end is inserted and fixed in a positioning hole opened on the outer guide frame. The guide rail is inserted and fixed to the support plate and is perpendicular to the support plate. The pressing plate is slidably assembled on the guide rail and its sliding position on the guide rail is controlled by an electric push rod on the guide rail.

[0009] In one technical solution, the front-drive positioning frame includes an electric push rod two, an electric push rod three, and a movable pressure plate; a slider is fixed at the end of the electric push rod two, the slider is slidably assembled in a guide groove, and is linked to the end of the electric push rod five, the slider electric push rod five controls the sliding position on the guide groove; a horizontal plate is fixed at the end of the electric push rod two away from the slider, a vertical plate is fixed on the horizontal plate, the vertical plate is fixed on the electric push rod three, and the electric push rod three and the electric push rod two are vertically distributed; multiple movable pressure plates are provided, and the multiple movable pressure plates are assembled together by an adjusting rail assembly; multiple One of the movable pressure plates is fixed at the end of the electric push rod three; the plasma spray gun is detachably mounted on the front drive positioning frame via a snap-fit; the movable pressure plate includes a pressing table with a cavity on it, inside which a finishing roller structure is installed, which is used to smooth wrinkles on the nickel mesh; the finishing roller structure includes a roller body controlled by a servo motor one and an electric push rod seven, which is mounted above the roller body and used to control the up and down position of the roller body; the finishing roller structure also includes a drive motor, which is mounted on the electric push rod seven and used to control the rotation angle of the roller body.

[0010] In one technical solution, the plasma spraying device for the nickel mesh electrode further includes a control system. The control system includes a control unit, which is electrically connected to electric actuators one, two, three, four, five, six, and seven, servo motor one, and servo motor two, respectively. The control unit is configured to calculate and determine the number, width, and arrangement of spraying paths based on the geometry of the nickel mesh to be sprayed and the preset spraying coverage area of ​​the plasma spray gun, and generate corresponding drive commands accordingly. The drive commands include:

[0011] The first drive command is used to control the extension and retraction of the electric push rod to push the outer guide frame on the rear drive positioning frame to slide along the positioning frame, so that a preset row distance is formed between the rear drive positioning frame and the front drive positioning frame, and the plasma spray gun is located within the row distance.

[0012] The second drive command is used to control the extension and retraction of the electric push rod five to adjust the sliding position of the front drive positioning frame and the plasma spray gun on the guide groove, so that the plasma spray gun forms the spraying path along the row spacing as it moves forward, thereby achieving row-by-row spraying.

[0013] The third drive command is used to control the extension and retraction of the electric push rod two to adjust the distance between the moving pressure plate and the pressing plate, thereby adjusting the width of the spraying path to adapt to different specifications of plasma spray guns;

[0014] The fourth drive command is used to control the electric push rod four and the electric push rod six to perform batch adjustment of the positioning points: after the plasma spray gun has finished spraying a row, the electric push rod four of a portion of the unit positioning plates is controlled to lift the tray, guide rail and pressing plate from the nickel mesh, and then the electric push rod six is ​​controlled to make the pressing plate slide along the guide rail to the position of the next spraying path. Then the electric push rod four is controlled to re-press the pressing plate against the nickel mesh; at the same time, another portion of the unit positioning plates is controlled to remain pressed. After the aforementioned portion has completed its reset, the remaining unit positioning plates are controlled to repeat the above actions, gradually distributing the positioning points of the entire positioning plate group to the new spraying path;

[0015] The fifth drive command is used to control the adjustment rail assembly to move multiple moving pressure plates to the corresponding positions according to the detected wrinkled areas on the nickel mesh surface before the spraying begins. Then, it controls the electric push rod seven to extend and retract so that the roller body is against the nickel mesh. Then, it controls the drive motor to drive the electric push rod seven and the roller body to rotate, and controls the servo motor to drive the roller body to rotate, so as to pull and smooth the wrinkles of the nickel mesh.

[0016] Another object of the present invention is to provide a plasma spraying method for a nickel mesh electrode, comprising the following steps:

[0017] Step 1: Nickel mesh pretreatment and positioning tensioning

[0018] The nickel mesh to be coated is placed inside the positioning frame. The nickel mesh is stretched and flattened by the peripheral clamping mechanism of the positioning frame, so that the surface of the nickel mesh is wrinkle-free and the tension is uniform, thus completing the initial positioning.

[0019] Step 2: Wrinkle Detection and Smoothing

[0020] Before the spraying begins, wrinkled areas on the nickel mesh surface are detected using an image sensor or a contact sensor.

[0021] Activate the adjustment rail assembly to move multiple movable pressure plates to the positions corresponding to the wrinkled areas;

[0022] The electric push rod seven is extended to make the roller body abut against the wrinkled surface of the nickel mesh;

[0023] Start the drive motor to drive the electric push rod seven and the roller to rotate. At the same time, start the servo motor to drive the roller to rotate, so that the roller pulls and flattens the nickel mesh along the wrinkle direction until the surface of the nickel mesh is completely flat.

[0024] Step 3: Adaptive adjustment of spray path width

[0025] Based on the model of the plasma spray gun currently in use and the preset spray coverage area, the required spray path width is calculated by the control unit;

[0026] Control the extension and retraction of the electric push rod two, adjust the distance between the moving pressure plate and the pressing plate, so that the width of the spray channel formed matches the coverage area of ​​the spray gun;

[0027] Step 4: Setting row spacing and planning spray path

[0028] The electric push rod extends and retracts, pushing the outer guide frame on the rear drive positioning frame to slide along the positioning frame, so that a preset row distance is formed between the rear drive positioning frame and the front drive positioning frame.

[0029] Position the plasma spray gun at the beginning of the row spacing, ready to spray;

[0030] Step 5: Row-by-row spraying and batch positioning point adjustment

[0031] S1, First row spraying

[0032] Start the electric push rod five to control the front drive positioning frame and plasma spray gun to slide at a constant speed on the guide groove, so that the plasma spray gun moves along the row spacing direction to form the first spraying path; during the spraying process, the rear drive positioning frame and the front drive positioning frame are located on both sides of the spraying path to rigidly lock the spraying area of ​​the nickel mesh and prevent the spraying powder from splashing to the adjacent area.

[0033] S2, Interline Switching and Batch Adjustment Positioning Point

[0034] After a row of spraying is completed, perform batch adjustment: divide the multiple unit positioning plates in the positioning plate group into at least two subgroups; first, control the electric push rod four of the unit positioning plate of the first subgroup to extend, lifting the support plate, guide rail and pressing plate from the nickel mesh; control the electric push rod six to drive the pressing plate to slide along the guide rail to the corresponding position of the next spraying path; then control the electric push rod four to retract, pressing the pressing plate back onto the nickel mesh; subsequently, control the unit positioning plate of the second subgroup in the same way to complete the positioning point migration; throughout the entire batch adjustment process, always keep the positioning point of at least one subgroup pressing the nickel mesh to prevent the nickel mesh from thermal deformation or displacement due to the instantaneous loss of all constraints;

[0035] S3, Outer guide frame reset and next row positioning

[0036] Simultaneously activate electric push rod six to keep the press plate in a fixed position, while controlling electric push rod one to push the outer guide frame to slide and reset along the guide hole, so that the outer guide frame is re-aligned above the press plate; electric push rod one continues to extend and retract, driving the rear drive positioning frame and the front drive positioning frame to move along the positioning frame to the next row position;

[0037] S4, Repeated spraying

[0038] Repeat steps S1 to S3 until the entire predetermined spraying path of the nickel mesh is evenly covered.

[0039] Step Six: Post-coating treatment and unloading

[0040] After the coating is completed, turn off the plasma spray gun and continue to cool the nickel mesh to room temperature on the back side; loosen the clamping mechanism of the positioning frame and remove the coated nickel mesh; transfer the nickel mesh into the alkaline activation tank for subsequent activation treatment.

[0041] Step 7: Self-learning and optimization of system parameters

[0042] The control unit records parameters such as nickel mesh size, plasma spray gun model, path width, row spacing, spraying speed, and substrate temperature during the current spraying process, and correlates them with the coating uniformity detection results. Through the built-in self-learning algorithm, it optimizes the path planning parameters for the next spraying, further improving the spraying uniformity.

[0043] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0044] 1. After the nickel mesh to be coated is placed inside the positioning frame, the positioning frame is used to tighten and flatten the nickel mesh for positioning. Then, two electric push rods are simultaneously activated. These electric push rods extend and retract, driving the rear and front drive positioning frames on the positioning frame to move along the positioning frame. During this process, the rear drive positioning frame positions the nickel mesh row by row. Because a row spacing is formed between the rear and front drive positioning frames, and the plasma spray gun is positioned within this row spacing, the forward movement of the plasma spray gun creates a spraying path, thus evenly dividing the nickel mesh into multiple spraying paths. The plasma spray gun follows the front drive positioning frame as it moves along the rear drive... The positioning frame moves synchronously, completing the spraying process along the spraying path one by one. This improves the rationality and uniformity of nickel mesh spraying, avoiding overlapping or gaps caused by missed spraying. Simultaneously, with the plasma spray gun positioned in the row spacing and the rear and front positioning frames on either side, the spraying area of ​​the nickel mesh can be locked, preventing thermal deformation of the nickel mesh during spraying and thus avoiding uneven spraying. Furthermore, the rear and front positioning frames, positioned on either side of the plasma spray gun, can block the spraying, preventing overlapping.

[0045] 2. After the nickel mesh to be coated is placed inside the positioning frame, the positioning frame is used to tighten and flatten the nickel mesh for positioning. The two positioning plate groups set inside the outer guide frame will activate a portion of multiple unit positioning plates after the plasma spray gun has finished spraying one row. The unit positioning plates use electric push rod four to lift the support plate, guide rail and pressing plate from the nickel mesh. Then, electric push rod six controls the pressing plate to slide on the guide rail. After the pressing plate enters the next spraying path, electric push rod four is restarted to extend and retract to press the pressing plate against the nickel mesh. At this time, the positioning plate group will activate the remaining portion of multiple unit positioning plates to repeat the above operation, completing the allocation of multiple unit positioning plates in the positioning plate group to another spraying path. This achieves stable positioning of the nickel mesh by adjusting the positioning points in batches, avoiding thermal deformation of the nickel mesh spraying area, which would cause uneven spraying path width when adjusting the positioning points uniformly.

[0046] 3. The position of the moving pressure plate is controlled by the extension and retraction of the electric push rod, so as to adjust the distance between the pressing plate and the moving pressure plate, thereby adjusting the width of the spraying path and adapting to different types of plasma spray guns;

[0047] 4. Before the nickel mesh is coated, use the adjusting rail assembly to adjust the position between multiple moving pressure plates. After the multiple moving pressure plates move to the wrinkled area of ​​the nickel mesh, start the extension and retraction of the electric push rod seven to press the roller against the nickel mesh. Then start the drive motor to drive the electric push rod seven and the roller to rotate so that the roller rotates in the direction of smoothing the wrinkles. Finally, start the servo motor to control the rotation of the roller to pull and smooth the wrinkles of the nickel mesh.

[0048] 5. The unit positioning plates in the positioning plate assembly are lifted, moved, and pressed in batches to adjust the positioning points in batches; the combined rear-drive positioning frame and front-drive positioning frame are located on both sides of the row spacing, locking the spraying area and locking the row spacing during each row of spraying; active thermal deformation compensation is achieved; when the nickel mesh is slightly expanded by heat in the spraying row, the rear-drive positioning frame and front-drive positioning frame on both sides of the row spacing will restrict the expansion direction, so that the expansion can only occur along the longitudinal direction of the spraying path without changing the row spacing width; when switching between rows, the positioning points adjusted in batches will absorb the small deformations remaining in the previous row; because only some positioning points are lifted, the remaining positioning points still press down on the nickel mesh, so that the nickel mesh can release stress in the relaxation area, while maintaining the reference in the holding area; combined with the electric push rod two to adjust the path width, the preset width of the next row can be dynamically fine-tuned according to the actual deformation of the previous row, realizing a closed loop of spraying, detection, and compensation;

[0049] 6. The electric push rod 2 adjusts the path width, and the batch adjustment of positioning points by multiple unit positioning plates realizes online width switching; when it is necessary to switch from a wide plasma spray gun to a narrow plasma spray gun, the distance between the pressing plate and the moving plate can be reduced by the electric push rod 2; the positioning points are adjusted in batches, and the nickel mesh is always pressed by most of the positioning points throughout the process, without wrinkles; the switching process can be completed in the gap between two rows of spraying without stopping the machine;

[0050] 7. The adjustment rail assembly, electric push rod 7, and roller rotation traction achieve wrinkle smoothing. The unit positioning plates in the combined positioning plate group are lifted, moved, and pressed in batches, forming a batch adjustment positioning. The combined rear-drive positioning frame and front-drive positioning frame block on both sides of the plasma spray gun. The smoothed nickel mesh has a uniform initial tension, which makes the resistance of the positioning point movement consistent during batch adjustment and avoids path deviation caused by local tension abrupt changes. The uniform tension also makes the gap between the blocking edge of the rear-drive positioning frame and the front-drive positioning frame and the nickel mesh extremely small, thereby almost completely blocking the lateral splashing of sprayed powder. The deformation mode of the smoothed nickel mesh when heated is more predictable, which makes the adaptive compensation algorithm able to calculate the compensation amount more accurately. Attached Figure Description

[0051] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0052] Figure 1 This is a schematic diagram of the structure of a plasma spraying device for a nickel mesh electrode according to one embodiment of the present invention;

[0053] Figure 2 This is a demonstration diagram of the plasma spraying apparatus for nickel mesh electrodes according to one embodiment of the present invention, showing the plasma spraying of nickel mesh electrodes.

[0054] Figure 3 This is a schematic diagram of the positioning planning frame in one embodiment of the present invention;

[0055] Figure 4 for Figure 2 Top view;

[0056] Figure 5 This is a schematic diagram of the positioning planning frame after the electric push rod is removed in one embodiment of the present invention;

[0057] Figure 6 This is a schematic diagram of the rear drive positioning frame in one embodiment of the present invention;

[0058] Figure 7 This is a schematic diagram of the structure of the outer guide frame in one embodiment of the present invention;

[0059] Figure 8 This is a schematic diagram of the positioning plate assembly in one embodiment of the present invention;

[0060] Figure 9 This is a schematic diagram of the front-drive positioning frame in one embodiment of the present invention;

[0061] Figure 10 This is a schematic diagram of the front-drive positioning frame in another embodiment of the present invention;

[0062] Figure 11 This is a schematic diagram of the positioning frame in one embodiment of the present invention.

[0063] In the attached diagram, the following are the reference numerals: 1. Positioning frame; 2. Positioning planning frame; 3. Nickel mesh; 4. Spraying path; 11. Positioning traction structure; 21. Plasma spray gun; 22. Positioning frame; 23. Electric push rod 1; 24. Rear drive positioning frame; 25. Front drive positioning frame; 241. Outer guide frame; 242. Positioning plate assembly; 243. Unit positioning plate; 251. Slider; 252. Electric push rod 2; 253. Horizontal plate; 254. Electric push rod 3; 255. Moving pressure plate; 256. Adjusting rail assembly; 257. Outer guide frame body; 2411. Positioning hole; 2412. Guide groove; 2413. Guide hole; 2414. Support plate; 2431. Electric push rod 4; 2432. Guide rail; 2433. Pressing plate; 2434. Finishing roller structure; 2561. Pressing table; 2562. Detailed Implementation

[0064] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without inventive effort are within the scope of protection of this invention.

[0065] In one embodiment of the present invention, such as Figures 1-5 As shown: A plasma spraying apparatus for nickel mesh electrodes includes a positioning frame 1 for positioning the nickel mesh 3, the positioning frame 1 being used for positioning the nickel mesh after it has been stretched and flattened;

[0066] The device also includes a positioning frame 2, which is slidably mounted on the positioning frame 1. The positioning frame 2 includes a plasma spray gun 21, a positioning frame 22, and an electric push rod 23. The positioning frame 22 is slidably mounted on the positioning frame 1. Two electric push rods 23 are provided and fixed on both sides of the positioning frame 1, and are assembled with the positioning frame 22. The positioning frame 22 can be moved back and forth along the positioning frame 1 by extending and retracting the electric push rods 23. The plasma spray gun 21 is used to perform plasma spraying on the nickel mesh 3.

[0067] Therefore, the nickel mesh 3 to be coated is first placed inside the positioning frame 1, and the positioning frame 1 is used to tighten and flatten the nickel mesh 3 for positioning; then, the two electric push rods 23 are started simultaneously, and the positioning frame 22 can be moved back and forth along the positioning frame 1 by the extension and retraction of the electric push rods 23; the positioning frame 22 drives the plasma spray gun 21 to move along the positioning frame 1, and the plasma spray gun 21 is used to perform plasma spraying on the nickel mesh 3;

[0068] The positioning frame 22 includes a rear-drive positioning frame 24 and two front-drive positioning frames 25. The two front-drive positioning frames 25 are symmetrically distributed and are slidably mounted on the rear-drive positioning frame 24. The plasma spray gun 21 is mounted on the front-drive positioning frame 25 and can move synchronously with the front-drive positioning frame 25 on the rear-drive positioning frame 24. The rear-drive positioning frame 24 is slidably mounted on the positioning frame 1. The rear-drive positioning frame 24 is used to position the nickel mesh 3 row by row and forms a row spacing with the front-drive positioning frame 25. This row spacing forms the spraying path 4 as the plasma spray gun 21 moves forward.

[0069] It should be added that: the plasma spray gun 21 is existing technology, and its detailed structure can be found in existing literature and journals. It can also be purchased directly on the market, or its components can be purchased on the market and assembled, etc. It is not what this invention is meant to protect, and will not be described in detail here.

[0070] In summary, the nickel mesh 3 to be coated is first placed inside the positioning frame 1, and then the positioning frame 1 is used to tighten and flatten the nickel mesh 3 for positioning. Afterwards, two electric push rods 23 are simultaneously activated. The electric push rods 23, through extension and retraction, drive the rear-drive positioning frame 24 and the front-drive positioning frame 25 on the positioning frame 22 to move along the positioning frame 1. During this process, the rear-drive positioning frame 24 positions the nickel mesh 3 row by row. Since there is a row spacing between the rear-drive positioning frame 24 and the front-drive positioning frame 25, and the plasma spray gun 21 is located within this row spacing, the plasma spray gun 21 can form a spraying path 4 as it moves forward, thus neatly and evenly dividing the nickel mesh 3 into multiple spraying paths 4. The plasma spray gun 21 follows the front-drive positioning frame 25... As the positioning frame 25 moves synchronously on the rear-drive positioning frame 24, it completes the spraying along the spraying path 4 one by one, improving the rationality and uniformity of the nickel mesh 3 spraying and avoiding spray overlap or gaps caused by missed spraying. At the same time, the plasma spray gun 21 is in the row spacing, and the rear-drive positioning frame 24 and the front-drive positioning frame 25 are on both sides of the row spacing, which can lock the spraying area of ​​the nickel mesh 3, preventing thermal deformation of the spraying area of ​​the nickel mesh 3 when the plasma spray gun 21 sprays the nickel mesh 3, which would lead to uneven spraying. In addition, the rear-drive positioning frame 24 and the front-drive positioning frame 25 can block the spraying of the plasma spray gun 21 on both sides, avoiding spray overlap.

[0071] In another embodiment of the present invention, such as Figures 5-7As shown: The rear drive positioning frame 24 includes an outer guide frame 241 and two positioning plate assemblies 242 disposed inside the outer guide frame 241; the two positioning plate assemblies 242 are symmetrically distributed inside the outer guide frame 241.

[0072] The outer guide frame 241 includes an outer guide frame body 2411, which is rectangular in shape. The outer guide frame body 2411 has a guide groove 2413 on the upper and lower sides of the side. The front drive positioning frame 25 is slidably mounted on the guide groove 2413 and its sliding position on the guide groove 2413 is controlled by an electric push rod 5 mounted inside the guide groove 2413.

[0073] The outer guide frame 2411 has a guide hole 2414 on each side, and the outer guide frame 2411 is slidably assembled on the positioning frame 1 through the guide hole 2414.

[0074] Therefore, two electric push rods 23 are activated simultaneously. The electric push rods 23 push the outer guide frame 241 on the rear drive positioning frame 24. The outer guide frame 241 slides on the positioning frame 1 through the guide hole 2414. This completes the movement of the electric push rods 23 along the positioning frame 1 by extending and retracting the rear drive positioning frame 24 and the front drive positioning frame 25 on the positioning frame 22. During this process, the rear drive positioning frame 24 is used to position the nickel mesh 3 row by row. Since there is a row spacing between the rear drive positioning frame 24 and the front drive positioning frame 25, and the plasma spray gun 21 is located in this row spacing... The electric push rod five is activated, which controls the sliding position of the front drive positioning frame 25 and the plasma spray gun 21 on the guide groove 2413. As the plasma spray gun 21 moves forward, the row spacing can form a spraying path 4, so that the nickel mesh 3 is neatly and evenly divided into multiple spraying paths 4. As the plasma spray gun 21 moves synchronously with the front drive positioning frame 25 on the rear drive positioning frame 24, the spraying is completed one by one along the spraying path 4, which improves the rationality and uniformity of the nickel mesh 3 spraying and avoids the situation of spraying overlap or missed spraying and gaps.

[0075] In another embodiment of the present invention, such as Figures 6-8 As shown: The positioning plate group 242 includes multiple unit positioning plates 243, which are distributed on one side inside the outer guide frame 241 and arranged in a straight line array.

[0076] The unit positioning plate 243 includes a support plate 2431, an electric push rod 2432, a guide rail 2433, and a pressing plate 2434. One end of the electric push rod 2432 is fixed on the support plate 2431, and the other end is inserted and fixed in the positioning hole 2412 opened on the outer guide frame 2411.

[0077] The guide rail 2433 is inserted and fixed on the support plate 2431 and is perpendicular to the support plate 2431; the pressing plate 2434 is slidably assembled on the guide rail 2433 and its sliding position on the guide rail 2433 is controlled by the electric push rod 6 provided on the guide rail 2433.

[0078] Therefore, after the nickel mesh 3 to be sprayed is placed inside the positioning frame 1, the positioning frame 1 is used to tighten and flatten the nickel mesh 3 for positioning. The two positioning plate groups 242 set inside the outer guide frame 241 will activate a number of unit positioning plates 243 after the plasma spray gun 21 has finished spraying one row. The unit positioning plates 243 use electric push rod four 2432 to lift the support plate 2431, guide rail 2433 and pressing plate 2434 from the nickel mesh 3. Then, electric push rod six controls the pressing plate 2434 to slide on the guide rail 2433. After the pressing plate 2434 enters the next spraying path 4, the electric push rod four 2432 is restarted to extend and retract to press the pressing plate 2434. The nickel mesh 3 is then pressed onto the nickel mesh 3. At this point, the positioning plate group 242 starts up again, and the remaining multiple unit positioning plates 243 repeat the above operation to complete the allocation of the multiple unit positioning plates 243 contained in the positioning plate group 242 to another spraying path 4 (taking four unit positioning plates 243 as an example, the first and third unit positioning plates 243 adjust their positioning points first, and the second and fourth unit positioning plates 243 adjust their positioning points after the first and third unit positioning plates 243 adjust their positioning points). This achieves stable positioning of the nickel mesh 3 by adjusting the positioning points in batches, avoiding thermal deformation of the nickel mesh 3 spraying area, which would cause uneven width of the spraying path 4 when adjusting the positioning points uniformly.

[0079] In another embodiment of the present invention, the nickel mesh 3 to be sprayed is first placed inside the positioning frame 1, and then the positioning frame 1 is used to tighten and flatten the nickel mesh 3 for positioning; the two positioning plate groups 242 set inside the outer guide frame 241 will activate a portion of multiple unit positioning plates 243 after the plasma spray gun 21 has finished spraying one row. The unit positioning plates 243 use electric push rod four 2432 to lift the support plate 2431, guide rail 2433 and pressing plate 2434 from the nickel mesh 3, and then use electric push rod six to control the pressing plate 2434 to slide on the guide rail 2433. After the pressing plate 2434 enters the next spraying path 4, the electric push rod four 2432 is restarted to extend and retract to press the pressing plate 2434 against the nickel mesh 3; at this time, the positioning plate Group 242 then restarts the remaining multiple unit positioning plates 243, repeating the above operation to complete the allocation of the multiple unit positioning plates 243 contained in the positioning plate group 242 to another spraying path 4; this achieves stable positioning of the nickel mesh 3 by adjusting the positioning points in batches, avoiding thermal deformation of the nickel mesh 3 in the spraying area, which would cause uneven width of the spraying path 4 when adjusting the positioning points uniformly; then, the two electric push rods 23 are activated, which push the outer guide frame 241 on the rear drive positioning frame 24. The outer guide frame 241 slides on the positioning frame 1 using the guide hole 2414. At this time, the electric push rod 6 is activated simultaneously to ensure that the outer guide frame 241 returns to the pressing plate 2434 when the pressing plate 2434 is fixed in position. Above, electric push rod 23 pushes the outer guide frame 241 on the rear drive positioning frame 24. The outer guide frame 241 slides on the positioning frame 1 through the guide hole 2414. The electric push rod 23, through extension and retraction, drives the rear drive positioning frame 24 and the front drive positioning frame 25 on the positioning frame 22 to move along the positioning frame 1. During this process, the rear drive positioning frame 24 is used to position the nickel mesh 3 row by row. Since there is a row spacing between the rear drive positioning frame 24 and the front drive positioning frame 25, and the plasma spray gun 21 is located in this row spacing, electric push rod 5 is activated. Electric push rod 5 controls the sliding position of the front drive positioning frame 25 and the plasma spray gun 21 on the guide groove 2413. As the plasma spray gun 21 moves forward, the row spacing can be formed into the spraying path 4, realizing the neat and uniform division of the nickel mesh 3 into multiple layers. The plasma spray gun 21 moves synchronously along the rear positioning frame 24 with the front positioning frame 25 following the front positioning frame 25, completing the spraying along the spraying path 4 one by one. This improves the rationality and uniformity of the nickel mesh 3 spraying and avoids the situation of spray overlap or gaps caused by missed spraying. At the same time, the plasma spray gun 21 is in the row spacing, and the rear positioning frame 24 and the front positioning frame 25 are on both sides of the row spacing, which can lock the spraying area of ​​the nickel mesh 3 and avoid the problem of uneven spraying caused by thermal deformation of the spraying area of ​​the nickel mesh 3 when the plasma spray gun 21 sprays the nickel mesh 3. In addition, the rear positioning frame 24 and the front positioning frame 25 can block the spraying of the plasma spray gun 21 on both sides and avoid the situation of spray overlap.

[0080] In another embodiment of the present invention, such as Figure 9 As shown: The front drive positioning frame 25 includes an electric push rod 252, an electric push rod 255, and a movable pressure plate 256;

[0081] The electric push rod 252 has a slider 251 fixed at its end. The slider 251 is slidably assembled in the guide groove 2413 and is linked to the end of the electric push rod 5. The slider 251 controls the sliding position of the electric push rod 5 on the guide groove 2413.

[0082] A horizontal plate 253 is fixed to the end of the electric push rod 252 away from the slider 251. A vertical plate 254 is fixed on the horizontal plate 253. The vertical plate 254 is fixed on the electric push rod 255. The electric push rod 255 and the electric push rod 252 are vertically distributed. The movable pressure plate 256 is fixed at the end of the electric push rod 255. The plasma spray gun 21 is detachably mounted on the front drive positioning frame 25 by a snap-fit.

[0083] Therefore, the rear-drive positioning frame 24 uses the pressing plate 2434 of the unit positioning plate 243 to position the nickel mesh 3 from one side of the spraying path 4, and the front-drive positioning frame 25 uses the moving pressure plate 256 to position the nickel mesh 3 from the other side of the spraying path 4. This ensures that the rear-drive positioning frame 24 and the front-drive positioning frame 25 form a row spacing through the pressing plate 2434 and the moving pressure plate 256, thus neatly and evenly dividing the nickel mesh 3 into multiple spraying paths 4. As the plasma spray gun 21 moves synchronously with the front-drive positioning frame 25 on the rear-drive positioning frame 24, spraying is completed one by one along the spraying path 4, improving the efficiency of the nickel mesh 3. The spraying process ensures rationality and uniformity, avoiding overlapping or gaps caused by missed spraying. Simultaneously, the plasma spray gun 21 is positioned in the middle of the row spacing, while the rear-drive positioning frame 24 and the front-drive positioning frame 25 are positioned on either side of the row spacing. This locks the spraying area of ​​the nickel mesh 3, preventing thermal deformation and uneven spraying during the spraying process. Furthermore, the pressing plate 2434 and the moving pressure plate 256 are positioned on either side of the plasma spray gun 21 to block the spraying and prevent overlapping.

[0084] The position of the moving pressure plate 256 is controlled by the extension and retraction of the electric push rod 252, so as to adjust the distance between the pressing plate 2434 and the moving pressure plate 256, thereby adjusting the width of the spraying path 4 and adapting to different types of plasma spray guns 21.

[0085] In another embodiment of the present invention, such as Figure 10As shown: The front drive positioning frame 25 includes an electric push rod 252, an electric push rod 255, and a movable pressure plate 256; the electric push rod 252 has a slider 251 fixed at its end, the slider 251 is slidably assembled in the guide groove 2413, and is linked to the end of the electric push rod 252, the slider 251 is controlled by the electric push rod 255 to slide in the guide groove 2413; a horizontal plate 253 is fixed at the end of the electric push rod 252 away from the slider 251, a vertical plate 254 is fixed on the horizontal plate 253, the vertical plate 254 is fixed on the electric push rod 255, and the electric push rod 252 and the electric push rod 255 are vertically distributed;

[0086] Multiple movable pressure plates 256 are provided, and the multiple movable pressure plates 256 are assembled together by adjusting rail assembly 257; one of the multiple movable pressure plates 256 is fixed at the end of electric push rod three 255; plasma spray gun 21 is detachably assembled on front drive positioning frame 25 by snap-fit; movable pressure plate 256 includes pressing table 2562, the pressing table 2562 has a cavity, and a sorting roller structure 2561 is installed inside the cavity. The sorting roller structure 2561 is used to smooth the wrinkles that appear on nickel mesh 3;

[0087] The finishing roller structure 2561 includes a roller body controlled by a servo motor and an electric push rod 7. The electric push rod 7 is mounted on the top of the roller body and is used to control the up and down position of the roller body. The finishing roller structure 2561 also includes a drive motor, which is mounted on the electric push rod 7 and is used to control the rotation angle of the roller body.

[0088] Therefore, before the nickel mesh 3 is to be sprayed, the position between the multiple movable pressure plates 256 is adjusted using the adjusting rail assembly 257. After the multiple movable pressure plates 256 move to the wrinkled area of ​​the nickel mesh 3, the electric push rod 7 is activated to extend and retract, and the roller body is pressed against the nickel mesh 3. Then, the drive motor is activated to drive the electric push rod 7 and the roller body to rotate, so that the roller body rotates in the direction of smoothing the wrinkles. Finally, the roller body rotation controlled by the servo motor 1 is activated to pull and smooth the wrinkles of the nickel mesh 3.

[0089] In one technical solution, the adjustment rail assembly 257 includes an X-axis adjustment rail, a Y-axis adjustment rail, and a Z-axis adjustment arm, which are assembled together. The X-axis adjustment rail, Y-axis adjustment rail, and Z-axis adjustment arm are combined to adjust the position of the moving pressure plate 256 in three-dimensional space.

[0090] In another embodiment of the present invention, such as Figure 1 and Figure 11 As shown: The positioning frame 1 is rectangular in shape, and multiple positioning traction structures 11 are provided inside the positioning frame 1. The multiple positioning traction structures 11 are used to pull the nickel mesh 3 straight in all directions.

[0091] The positioning traction structure 11 includes a clamp, a traction rope, a take-up roller, and a second servo motor. The clamp is used to hold the nickel mesh 3. One end of the traction rope is connected to the clamp, and the other end is wound onto the take-up roller. The take-up roller is fixed to the output shaft of the second servo motor via a coupling.

[0092] It should be added that: electric actuator 1 (23), electric actuator 2 (252), electric actuator 3 (255), electric actuator 4 (2432), electric actuator 5, and electric actuator 6, as well as their power supply and wiring methods, are all existing technologies. For example, they include a servo motor 3, a reduction mechanism, a lead screw, a nut, and an actuator tube, etc. Their detailed structures can be found in existing literature and journals, and they can also be purchased directly from the market, or assembled from components purchased from the market, etc.; they are not what this invention is intended to protect, and will not be described in detail here.

[0093] In another embodiment of the present invention, the plasma spraying device for the nickel mesh electrode further includes a control system, which includes a control unit. The control unit is electrically connected to electric push rod 1 23, electric push rod 252, electric push rod 3 255, electric push rod 4 2432, electric push rod 5, electric push rod 6, electric push rod 7, servo motor 1, and servo motor 2, respectively. The control unit is configured to calculate and determine the number, width, and arrangement of spraying paths 4 based on the geometric dimensions of the nickel mesh 3 to be sprayed and the preset spraying coverage area of ​​the plasma spray gun 21, and generate corresponding driving commands accordingly. The driving commands include:

[0094] The first drive command is used to control the extension and retraction of the electric push rod 23 to push the outer guide frame 241 on the rear drive positioning frame 24 to slide along the positioning frame 1, so that a preset row spacing is formed between the rear drive positioning frame 24 and the front drive positioning frame 25, and the plasma spray gun 21 is located within the row spacing.

[0095] The second drive command is used to control the extension and retraction of the electric push rod five to adjust the sliding position of the front drive positioning frame 25 and the plasma spray gun 21 on the guide groove 2413, so that the plasma spray gun 21 forms the spraying path 4 along the row spacing as it moves forward, thereby achieving row-by-row spraying.

[0096] The third driving command is used to control the extension and retraction of the electric push rod 252 to adjust the distance between the moving pressure plate 256 and the pressing plate 2434, thereby adjusting the width of the spraying path 4 to adapt to different specifications of plasma spray guns 21.

[0097] The fourth drive command is used to control the electric push rod four 2432 and the electric push rod six to perform batch adjustment of the positioning points: after the plasma spray gun 21 has finished spraying one row, the electric push rod four 2432 of a portion of the unit positioning plates 243 is controlled to lift the support plate 2431, guide rail 433 and pressing plate 2434 from the nickel mesh 3, and then the electric push rod six is ​​controlled to make the pressing plate 2434 slide along the guide rail 2433 to the position of the next spraying path 4. Then the electric push rod four 2432 is controlled to press the pressing plate 2434 back onto the nickel mesh 3; at the same time, the other portion of the unit positioning plates 243 is controlled to remain in the pressing state. After the aforementioned portion has completed the reset, the remaining unit positioning plates 243 are controlled to repeat the above actions to gradually distribute the positioning points of the entire positioning plate group 242 to the new spraying path 4.

[0098] The fifth drive command is used to control the adjustment rail assembly 257 to move multiple moving pressure plates 256 to corresponding positions according to the detected wrinkled areas on the surface of the nickel mesh 3 before the spraying begins. Then, the electric push rod 7 is controlled to extend and retract to make the roller body abut against the nickel mesh 3. The drive motor is then controlled to drive the electric push rod 7 and the roller body to rotate, and the servo motor is controlled to drive the roller body to rotate in order to pull and smooth the wrinkles of the nickel mesh 3.

[0099] Furthermore, the control unit includes a memory and a processor. The memory stores a mapping table of nickel mesh 3 size and plasma spray gun 21 coverage area. The processor automatically calculates the optimal row spacing and spray path width based on the mapping table and the real-time input nickel mesh size parameters.

[0100] Furthermore, the control unit is also configured to monitor the moving speed of the plasma spray gun 21 and the surface temperature of the nickel mesh 3 in real time during the spraying process, and dynamically adjust the extension and retraction speeds of the electric push rod 1 23 and the electric push rod 5 according to the monitoring results, so as to control the amount of heat input within the row spacing and prevent the nickel mesh 3 from thermally deforming.

[0101] Furthermore, in the fourth driving command, the control unit is configured to divide the multiple unit positioning plates 243 in the positioning plate group 242 into at least two subgroups, and to alternately control each subgroup to perform lift-move-press actions according to a time sequence, so that at least one subgroup maintains pressing and positioning of the nickel mesh 3 at any given time, thereby maintaining the overall stability of the nickel mesh 3 when the positioning path is changed.

[0102] Furthermore, the control unit is also configured to simultaneously control the electric push rod 6 to keep the position of the pressing plate 2434 fixed when the electric push rod 23 pushes the outer guide frame 241 to reset, so that the outer guide frame 241 slides back to reset relative to the pressing plate 2434 for seamless connection of the spraying path.

[0103] Furthermore, the control unit is also configured to automatically calculate the extension and retraction of the electric push rod 252 according to the model of the plasma spray gun 21 and the preset spray width, and control the electric push rod 252 to precisely adjust the distance between the moving pressure plate 256 and the pressing plate 2434 to form a spray channel with variable width.

[0104] Furthermore, the control unit is also configured to, when activating the wrinkle smoothing function, first obtain the wrinkle position and direction on the surface of the nickel mesh 3 through an image sensor, and then control the position of the adjustment rail assembly 257, the abutting force of the electric push rod 7, the speed of the drive motor and the rotation angle of the servo motor respectively, for adaptive wrinkle smoothing.

[0105] Furthermore, the control unit is also configured to synchronously control the electric push rod 255, the servo motor 1, and the drive motor during the execution of the second drive command, so as to adjust the spraying angle and height of the plasma spray gun 21, so that the width of the spraying path 4 and the coating thickness remain constant.

[0106] In summary: the unit positioning plates 243 in the positioning plate assembly 242 are lifted, moved, and pressed in batches to achieve batch adjustment of positioning points; the combined rear-drive positioning frame 24 and front-drive positioning frame 25 are located on both sides of the row spacing, locking the spraying area and locking the row spacing during row spraying; active thermal deformation compensation is achieved; when the nickel mesh 3 is slightly expanded by heat in the spraying row, the rear-drive positioning frame 24 and front-drive positioning frame 25 on both sides of the row spacing will restrict the expansion direction, so that the expansion can only occur along the longitudinal direction of the spraying path without changing the row spacing width; when switching between rows, the positioning points adjusted in batches will absorb the small deformations remaining in the previous row; because only some positioning points are lifted, the remaining positioning points still press down on the nickel mesh 3, so that the nickel mesh 3 can release stress in the relaxation area, while maintaining the reference in the holding area; combined with the electric push rod 252 to adjust the path width, the preset width of the next row can be dynamically fine-tuned according to the actual deformation of the previous row, realizing a closed loop of spraying, detection, and compensation;

[0107] The electric push rod 252 adjusts the path width, and the batch adjustment of positioning points of multiple unit positioning plates 243 realizes online width switching. When it is necessary to switch from a wide plasma spray gun 21 to a narrow plasma spray gun 21, the distance between the pressing plate 2434 and the moving pressure plate 256 can be reduced first by the electric push rod 252. The positioning points are adjusted in batches. Throughout the process, the nickel mesh 3 is always pressed by most of the positioning points, and no wrinkles are generated. The switching process can be completed in the gap between two rows of spraying without stopping the machine.

[0108] The adjustment rail assembly 257, the electric push rod 7, and the roller rotation traction achieve wrinkle smoothing. The unit positioning plates 243 in the combined positioning plate assembly 242 are lifted, moved, and pressed in batches, forming a batch adjustment positioning. The combined rear drive positioning frame 24 and front drive positioning frame 25 block on both sides of the plasma spray gun 21. The smoothed nickel mesh 3 has a uniform initial tension, which makes the resistance of the positioning point movement consistent during batch adjustment and avoids path deviation caused by local tension abrupt changes. The uniform tension also makes the gap between the blocking edges of the rear drive positioning frame 24 and the front drive positioning frame 25 and the nickel mesh 3 extremely small, thereby almost completely blocking the lateral splashing of the sprayed powder. The deformation mode of the smoothed nickel mesh 3 when heated is more predictable, which makes the adaptive compensation algorithm able to calculate the compensation amount more accurately.

[0109] In another embodiment of the present invention, a plasma spraying method for a nickel mesh electrode is provided, comprising the following steps:

[0110] Step 1: Nickel Mesh 3 Pretreatment and Positioning Tensioning

[0111] The nickel mesh 3 to be sprayed is placed inside the positioning frame 1. The nickel mesh 3 is stretched and flattened by the peripheral clamping mechanism of the positioning frame 1, so that the surface of the nickel mesh 3 is wrinkle-free and the tension is uniform, thus completing the initial positioning.

[0112] Step 2: Wrinkle Detection and Smoothing

[0113] Before the spraying begins, the wrinkled areas on the surface of the nickel mesh 3 are detected by an image sensor or a contact sensor;

[0114] Start the adjustment rail assembly 257 to move multiple movable pressure plates 256 to the positions corresponding to the wrinkled areas;

[0115] The electric push rod 7 is extended to make the roller body abut against the wrinkled surface of the nickel mesh 3;

[0116] Start the drive motor to drive the electric push rod 7 and the roller to rotate. At the same time, start the servo motor to drive the roller to rotate, so that the roller pulls and flattens the nickel mesh 3 along the wrinkle direction until the surface of the nickel mesh 3 is completely flat.

[0117] Step 3: Adaptive adjustment of spray path width

[0118] Based on the model of the plasma spray gun 21 currently in use and the preset spray coverage area, the required spray path 4 width is calculated by the control unit;

[0119] Control the extension and retraction of the electric push rod 252, and adjust the distance between the moving pressure plate 256 and the pressing plate 2434 so that the width of the spraying channel is matched with the coverage of the spray gun.

[0120] Step 4: Setting row spacing and planning spray path

[0121] The electric push rod 23 is extended and retracted, pushing the outer guide frame 241 on the rear drive positioning frame 24 to slide along the positioning frame 1, so that a preset row distance is formed between the rear drive positioning frame 24 and the front drive positioning frame 25.

[0122] Position the plasma spray gun 21 at the beginning of the row spacing, ready to spray;

[0123] Step 5: Row-by-row spraying and batch positioning point adjustment

[0124] S1, First row spraying

[0125] Start the electric push rod five to control the front drive positioning frame 25 and plasma spray gun 21 to slide at a constant speed on the guide groove 2413, so that the plasma spray gun 21 moves along the row spacing direction to form the first spraying path 4; during the spraying process, the rear drive positioning frame 24 and the front drive positioning frame 25 are located on both sides of the spraying path 4 respectively, rigidly locking the spraying area of ​​the nickel mesh 3 and blocking the spraying powder from splashing to the adjacent area;

[0126] S2, Interline Switching and Batch Adjustment Positioning Point

[0127] After a row of spraying is completed, a batch adjustment operation is performed: the multiple unit positioning plates 243 in the positioning plate group 242 are divided into at least two subgroups; first, the electric push rod four 2432 of the unit positioning plate 243 of the first subgroup is extended to lift the support plate 2431, guide rail 2433 and pressing plate 2434 from the nickel mesh 3; the electric push rod six drives the pressing plate 2434 to slide along the guide rail 2433 to the corresponding position of the next spraying path 4; then the electric push rod four 2432 is retracted to press the pressing plate 2434 back onto the nickel mesh 3; subsequently, the unit positioning plate 243 of the second subgroup is controlled in the same way to complete the positioning point migration; throughout the entire batch adjustment process, at least one subgroup's positioning point is always pressed against the nickel mesh 3 to prevent the nickel mesh 3 from thermal deformation or displacement due to the instantaneous loss of all constraints;

[0128] S3, Outer guide frame reset and next row positioning

[0129] Simultaneously activate electric push rod six to keep the press plate 2434 in a fixed position, while controlling electric push rod one 23 to push the outer guide frame 241 to slide and reset along the guide hole 2414, so that the outer guide frame 241 is re-aligned above the press plate 2434; electric push rod one 23 continues to extend and retract, driving the rear drive positioning frame 24 and the front drive positioning frame 25 to move along the positioning frame 1 to the next row position.

[0130] S4, Repeated spraying

[0131] Repeat steps S1 to S3 until all predetermined spraying paths 4 of the nickel mesh 3 are evenly covered.

[0132] Step Six: Post-coating treatment and unloading

[0133] After the spraying is completed, turn off the plasma spray gun 21 and continue to cool the nickel mesh 3 to room temperature on the back side; loosen the clamping mechanism of the positioning frame 1 and remove the nickel mesh 3 that has been sprayed; transfer the nickel mesh 3 into the alkaline activation tank for subsequent activation treatment;

[0134] Step 7: Self-learning and optimization of system parameters

[0135] The control unit records parameters such as nickel mesh size, plasma spray gun model 21, path width, row spacing, spraying speed, and substrate temperature during the current spraying process, and correlates them with the coating uniformity detection results. Through the built-in self-learning algorithm, it optimizes the path planning parameters for the next spraying, further improving the spraying uniformity.

[0136] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A plasma spraying apparatus for nickel mesh electrodes, comprising a positioning frame (1) for positioning a nickel mesh (3), the positioning frame (1) being used for positioning the nickel mesh after it has been stretched and flattened; characterized in that, The device also includes a positioning frame (2), which is slidably mounted on the positioning frame (1); the positioning frame (2) includes a plasma spray gun (21), a positioning frame (22) and an electric push rod (23), the positioning frame (22) is slidably mounted on the positioning frame (1); two electric push rods (23) are provided and fixed on both sides of the positioning frame (1) respectively, and are assembled together with the positioning frame (22); the positioning frame (22) can be driven to reciprocate along the positioning frame (1) by the extension and retraction of the electric push rod (23); the plasma spray gun (21) is used to perform plasma spraying on the nickel mesh (3); The positioning frame (22) includes a rear positioning frame (24) and two front positioning frames (25). The two front positioning frames (25) are symmetrically distributed and are slidably mounted on the rear positioning frame (24). The plasma spray gun (21) is mounted on the front positioning frame (25) and can move synchronously with the front positioning frame (25) on the rear positioning frame (24). The rear positioning frame (24) is slidably mounted on the positioning frame (1). The rear positioning frame (24) is used to position the nickel mesh (3) row by row and forms a row spacing with the front positioning frame (25). This row spacing forms the spraying path (4) as the plasma spray gun (21) moves forward.

2. The plasma spraying apparatus for nickel mesh electrodes according to claim 1, characterized in that, The rear drive positioning frame (24) includes an outer guide frame (241) and two positioning plate groups (242) disposed inside the outer guide frame (241); the two positioning plate groups (242) are symmetrically distributed inside the outer guide frame (241); The outer guide frame (241) includes an outer guide frame body (2411), which is rectangular in shape. The outer guide frame body (2411) has a guide groove (2413) on the upper and lower sides of the side. The front drive positioning frame (25) is slidably mounted on the guide groove (2413) and its sliding position on the guide groove (2413) is controlled by an electric push rod five mounted inside the guide groove (2413). A guide hole (2414) is provided on each side of the outer guide frame (2411), and the outer guide frame (2411) is slidably assembled on the positioning frame (1) through the guide hole (2414).

3. The plasma spraying apparatus for nickel mesh electrodes according to claim 2, characterized in that, The positioning plate group (242) includes multiple unit positioning plates (243), which are distributed on one side inside the outer guide frame (241) and arranged in a straight line array. The unit positioning plate (243) includes a support plate (2431), an electric push rod four (2432), a guide rail (2433) and a pressing plate (2434). One end of the electric push rod four (2432) is fixed on the support plate (2431), and the other end is inserted and fixed in the positioning hole (2412) opened on the outer guide frame (2411). The guide rail (2433) is inserted and fixed on the tray (2431) and is perpendicular to the tray (2431); the pressing plate (2434) is slidably assembled on the guide rail (2433) and its sliding position on the guide rail (2433) is controlled by the electric push rod six provided on the guide rail (2433).

4. The plasma spraying apparatus for nickel mesh electrodes according to claim 3, characterized in that, The front drive positioning frame (25) includes electric push rod two (252), electric push rod three (255) and movable pressure plate (256); The electric push rod 2 (252) has a slider (251) fixed at its end. The slider (251) is slidably assembled in the guide groove (2413) and linked to the end of the electric push rod 5. The slider (251) is controlled by the electric push rod 5 to slide in the guide groove (2413). A horizontal plate (253) is fixed to the end of the electric push rod 2 (252) away from the slider (251). A vertical plate (254) is fixed on the horizontal plate (253). The vertical plate (254) is fixed on the electric push rod 3 (255). The electric push rod 3 (255) and the electric push rod 2 (252) are vertically distributed. The movable pressure plate (256) is fixed at the end of the electric push rod 3 (255). The plasma spray gun (21) is detachably mounted on the front drive positioning frame (25) by a snap-fit.

5. The plasma spraying apparatus for nickel mesh electrodes according to claim 3, characterized in that, The front drive positioning frame (25) includes an electric push rod two (252), an electric push rod three (255), and a movable pressure plate (256); the electric push rod two (252) has a slider (251) fixed at its end, the slider (251) is slidably assembled in the guide groove (2413), and is linked to the end of the electric push rod five, the slider (251) is controlled by the electric push rod five to slide in the guide groove (2413); the end of the electric push rod two (252) away from the slider (251) is fixed with a horizontal plate (253), the horizontal plate (253) is fixed with a vertical plate (254), the vertical plate (254) is fixed on the electric push rod three (255), and the electric push rod three (255) and the electric push rod two (252) are vertically distributed; Multiple movable pressure plates (256) are provided, and the multiple movable pressure plates (256) are assembled together by adjusting rail assembly (257); one of the multiple movable pressure plates (256) is fixed at the end of electric push rod three (255); plasma spray gun (21) is detachably mounted on front drive positioning frame (25) by snap-fit; movable pressure plate (256) includes pressing table (2562), the pressing table (2562) has a cavity, and a finishing roller structure (2561) is installed inside the cavity. The finishing roller structure (2561) is used to smooth the wrinkles that appear on the nickel mesh (3); The finishing roller structure (2561) includes a roller body controlled by a servo motor and an electric push rod seven. The electric push rod seven is mounted on the top of the roller body and is used to control the up and down position of the roller body. The finishing roller structure (2561) also includes a drive motor, which is mounted on the electric push rod seven and is used to control the rotation angle of the roller body.

6. The plasma spraying apparatus for nickel mesh electrodes according to claim 5, characterized in that, The adjustment rail assembly (257) includes an X-axis adjustment rail, a Y-axis adjustment rail and a Z-axis adjustment arm, which are assembled together. The X-axis adjustment rail, Y-axis adjustment rail and Z-axis adjustment arm are combined to adjust the position of the moving pressure plate (256) in three-dimensional space.

7. The plasma spraying apparatus for nickel mesh electrodes according to claim 6, characterized in that, The positioning frame (1) is rectangular in shape, and multiple positioning traction structures (11) are provided inside the positioning frame (1). The multiple positioning traction structures (11) are used to pull the nickel mesh (3) straight in all directions. The positioning traction structure (11) includes a clamp, a traction rope, a take-up roller and a second servo motor. The clamp is used to hold the nickel mesh (3). One end of the traction rope is connected to the clamp, and the other end is wound onto the take-up roller. The take-up roller is fixed to the output shaft of the second servo motor via a coupling.

8. The plasma spraying apparatus for nickel mesh electrodes according to claim 7, characterized in that, It also includes a control system, which includes a control unit. The control unit is electrically connected to electric push rod 1 (23), electric push rod 2 (252), electric push rod 3 (255), electric push rod 4 (2432), electric push rod 5, electric push rod 6, electric push rod 7, servo motor 1, and servo motor 2, respectively. The control unit is configured to calculate and determine the number, width, and arrangement of the spraying paths (4) based on the geometric dimensions of the nickel mesh (3) to be sprayed and the preset spraying coverage of the plasma spray gun (21), and generate corresponding drive commands accordingly. The drive commands include: The first driving command is used to control the extension and retraction of the electric push rod (23) to push the outer guide frame (241) on the rear drive positioning frame (24) to slide along the positioning frame (1), so that a preset row spacing is formed between the rear drive positioning frame (24) and the front drive positioning frame (25), and the plasma spray gun (21) is located within the row spacing. The second drive command is used to control the extension and retraction of the electric push rod five to adjust the sliding position of the front drive positioning frame (25) and the plasma spray gun (21) on the guide groove (2413), so that the plasma spray gun (21) forms the spraying path (4) along the row spacing as it moves forward, and realizes row-by-row spraying. The third driving command is used to control the extension and retraction of the electric push rod (252) to adjust the distance between the moving pressure plate (256) and the pressing plate (2434), thereby adjusting the width of the spraying path (4) to adapt to different specifications of plasma spray guns (21). The fourth drive command is used to control the electric push rod four (2432) and the electric push rod six to perform batch adjustment of the positioning points: after the plasma spray gun (21) has finished spraying a row, the electric push rod four (2432) of a part of the unit positioning plate (243) is controlled to lift the tray (2431), guide rail (433) and pressing plate (2434) from the nickel mesh (3), and then the electric push rod six is ​​controlled to slide the pressing plate (2434) along the guide rail (2433) to the position of the next spraying path (4), and then the electric push rod four (2432) is controlled to press the pressing plate (2434) back onto the nickel mesh (3); at the same time, the other part of the unit positioning plate (243) is controlled to remain in the pressing state. After the aforementioned part has completed the reset, the remaining unit positioning plate (243) is controlled to repeat the above action to gradually distribute the positioning points of the entire positioning plate group (242) to the new spraying path (4). The fifth drive command is used to control the adjustment rail assembly (257) to move multiple moving pressure plates (256) to the corresponding positions according to the detected wrinkled areas on the surface of the nickel mesh (3) before the spraying begins. Then, the electric push rod seven is controlled to extend and retract so that the roller body abuts against the nickel mesh (3). The drive motor is then controlled to drive the electric push rod seven and the roller body to rotate, and the servo motor is controlled to drive the roller body to rotate in order to pull and smooth the wrinkles of the nickel mesh (3).

9. The plasma spraying apparatus for nickel mesh electrodes according to claim 8, characterized in that, The control unit includes a memory and a processor. The memory stores a mapping table of nickel mesh (3) size and plasma spray gun (21) coverage area. The processor automatically calculates the optimal row spacing and spray path width based on the mapping table and the real-time input nickel mesh size parameters. The control unit is also configured to monitor the moving speed of the plasma spray gun (21) and the surface temperature of the nickel mesh (3) in real time during the spraying process, and dynamically adjust the extension and retraction speed of the electric push rod one (23) and the electric push rod five according to the monitoring results, so as to control the amount of heat input within the row spacing and prevent the nickel mesh (3) from thermally deformed. The control unit is also configured to simultaneously control the electric push rod six to keep the position of the pressing plate (2434) fixed when the electric push rod one (23) pushes the outer guide frame (241) to reset, so that the outer guide frame (241) slides and resets relative to the pressing plate (2434) for seamless connection of the spraying path; The control unit is also configured to automatically calculate the extension and retraction of the electric push rod two (252) according to the model of the plasma spray gun (21) and the preset spray width, and control the electric push rod two (252) to precisely adjust the distance between the moving pressure plate (256) and the pressing plate (2434) to form a spray channel with variable width.

10. A plasma spraying method for a nickel mesh electrode according to claim 9, characterized in that, Includes the following steps: Step 1: Nickel mesh (3) pretreatment and positioning tension Place the nickel mesh (3) to be sprayed into the positioning frame (1), and use the peripheral clamping mechanism of the positioning frame (1) to tighten and flatten the nickel mesh (3) so that the surface of the nickel mesh (3) is wrinkle-free and the tension is uniform, thus completing the initial positioning. Step 2: Wrinkle Detection and Smoothing Before the spraying begins, the wrinkled areas on the surface of the nickel mesh (3) are detected by an image sensor or a contact sensor; Start the adjustment rail assembly (257) to move multiple movable pressure plates (256) to the positions corresponding to the wrinkled areas; The electric push rod 7 is extended so that the roller body abuts against the wrinkled surface of the nickel mesh (3); Start the drive motor to drive the electric push rod 7 and the roller to rotate. At the same time, start the servo motor to drive the roller to rotate, so that the roller pulls and flattens the nickel mesh (3) along the wrinkle direction until the surface of the nickel mesh (3) is completely flat. Step 3: Adaptive adjustment of spray path width Based on the model of the plasma spray gun (21) currently in use and the preset spray coverage area, the required spray path (4) width is calculated by the control unit; Control the extension and retraction of the electric push rod 2 (252) to adjust the distance between the moving pressure plate (256) and the pressing plate (2434) so ​​that the width of the spraying channel is matched with the coverage of the spray gun; Step 4: Setting row spacing and planning spray path Control the extension and retraction of the electric push rod (23) to push the outer guide frame (241) on the rear drive positioning frame (24) to slide along the positioning frame (1), so that a preset row distance is formed between the rear drive positioning frame (24) and the front drive positioning frame (25); Position the plasma spray gun (21) at the beginning of the row spacing, ready to spray; Step 5: Row-by-row spraying and batch positioning point adjustment S1, First row spraying Start the electric push rod five to control the front drive positioning frame (25) and plasma spray gun (21) to slide at a constant speed on the guide groove (2413), so that the plasma spray gun (21) moves along the row spacing direction to form the first spraying path (4); during the spraying process, the rear drive positioning frame (24) and the front drive positioning frame (25) are located on both sides of the spraying path (4) respectively, to rigidly lock the spraying area of ​​the nickel mesh (3) and block the spraying powder from splashing to the adjacent area; S2, Interline Switching and Batch Adjustment Positioning Point After a row of spraying is completed, a batch adjustment operation is performed: the multiple unit positioning plates (243) in the positioning plate group (242) are divided into at least two subgroups; first, the electric push rod four (2432) of the unit positioning plate (243) of the first subgroup is extended to lift the support plate (2431), guide rail (2433) and pressing plate (2434) from the nickel mesh (3); the electric push rod six is ​​controlled to drive the pressing plate (2434) to slide along the guide rail (2433) to the corresponding position of the next spraying path (4); then the electric push rod four (2432) is controlled to retract to press the pressing plate (2434) back onto the nickel mesh (3); subsequently, the unit positioning plate (243) of the second subgroup is controlled in the same way to complete the positioning point migration; throughout the entire batch adjustment process, at least one subgroup's positioning point is always pressed against the nickel mesh (3) to prevent the nickel mesh (3) from thermal deformation or displacement due to the instantaneous loss of all constraints; S3, Outer guide frame reset and next row positioning Simultaneously start the electric push rod six, keep the press plate (2434) in a fixed position, and at the same time control the electric push rod one (23) to push the outer guide frame (241) to slide and reset along the guide hole (2414), so that the outer guide frame (241) is re-aligned above the press plate (2434); the electric push rod one (23) continues to extend and retract, driving the rear drive positioning frame (24) and the front drive positioning frame (25) to move along the positioning frame (1) to the next row position; S4, Repeated spraying Repeat steps S1 to S3 until all predetermined spraying paths (4) of the nickel mesh (3) are uniformly covered; Step Six: Post-coating treatment and unloading After the spraying is completed, turn off the plasma spray gun (21) and continue to cool the nickel mesh (3) to room temperature on the back side; loosen the clamping mechanism of the positioning frame (1) and remove the nickel mesh (3) that has been sprayed; transfer the nickel mesh (3) into the alkaline activation tank for subsequent activation treatment; Step 7: Self-learning and optimization of system parameters The control unit records parameters such as nickel mesh size, plasma spray gun (21) model, path width, row spacing, spraying speed, and substrate temperature during the current spraying process, and associates them with the coating uniformity detection results; through the built-in self-learning algorithm, it optimizes the path planning parameters for the next spraying, further improving the spraying uniformity.

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