Intelligent anti-icing coating system and method based on vision and encoder feedback

Abstract

This invention belongs to the field of cable coating technology and discloses an intelligent anti-icing coating system and method based on vision and encoder feedback. The intelligent anti-icing coating system includes a robot platform, a magnetic encoder, an atomizing spraying device, a real-time monitoring device, an image transmission vision assistance system, and a control device. The robot platform is equipped with drive wheels, the magnetic encoder is located on one side of the drive wheels, the real-time monitoring device is located on top of the atomizing spraying device, and the control device is communicatively connected to the atomizing spraying device, the real-time monitoring device, and the magnetic encoder. This invention can significantly improve the uniformity, controllability, and safety of coating operations, achieving high-quality and high-efficiency intelligent operation and maintenance.

Description

Technical Field

[0001] This invention relates to the field of cable coating technology, and specifically to an intelligent anti-icing coating system and method based on vision and encoder feedback. Background Technology

[0002] In anti-icing maintenance of cables (such as power transmission cables, bridge cables, and cableway ropes), coating treatment is a key means to improve their anti-icing ability. Currently, the mainstream coating methods mainly include manual brushing and automatic machine spraying. Although manual brushing can improve the uniformity of the coating, it is limited by the high-altitude working environment and has drawbacks such as low work efficiency, high safety risks, and reliance on the operator's experience for quality, making it difficult to meet the needs of large-scale, standardized operation and maintenance.

[0003] Currently, automated coating robots have become a key technology for improving efficiency and safety. However, existing coating technologies generally lack the ability to monitor and dynamically adjust the coating process in real time. Operators cannot know the actual coating condition on the cable surface and can only perform open-loop operations based on preset parameters, resulting in a high degree of uncertainty in the coating effect and making it difficult to guarantee the reliability and consistency of anti-icing treatment. For example, CN202310998702 discloses a coating robot with a ring-shaped rotating spray head, adjustable opening, and closed-loop parameter control, which can adjust the spray thickness and temperature according to the material type and environmental conditions. Although it improves the coating uniformity and adaptability to a certain extent, this type of solution still has obvious shortcomings: it relies solely on spraying to form a film, has a simple structure, lacks physical homogenization treatment of the wet film, and is difficult to avoid the coating from flowing, accumulating, or unevenly covering due to gravity or wind. At the same time, its quality control is based on indirect parameter calculations (such as flow rate and speed), without direct observation of the actual coating state, and cannot identify real defects such as missed coating and bubbles. Furthermore, under complex operating conditions such as strong winds at high altitudes or sudden changes in conductor diameter, the system is difficult to dynamically compensate, which can easily lead to local coating failure.

[0004] In summary, existing coating methods have certain shortcomings and defects in terms of coating uniformity, operational safety, and process controllability. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent anti-icing coating system and method based on vision and encoder feedback to overcome the problems existing in the prior art. This invention can significantly improve the uniformity, controllability and safety of coating operations, and realize high-quality and high-efficiency intelligent operation and maintenance.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the present invention provides an intelligent anti-icing coating system based on vision and encoder feedback, comprising: A robot platform, equipped with drive wheels, for moving along the target cable; A magnetic encoder, located on one side of the drive wheel, is used to detect the number of rotations of the drive wheel in order to calculate the travel distance of the robot platform; An atomizing spraying device, mounted on a robot platform, is used to spray anti-icing coating onto the surface of the target cable. A real-time monitoring device is positioned facing the surface of the target cable. The real-time monitoring device is connected to the atomizing spraying device and is located on top of the atomizing spraying device. It is used to collect image information of the coating area. The image transmission vision assistance system is used to perform image recognition and positioning of the target cable, and output deviation information to guide the robot platform to align with the target cable; The control device, located on the robot platform, is connected to the atomizing spraying device, the real-time monitoring device, and the magnetic encoder. It is used to receive travel distance and spraying flow data to calculate paint consumption, and to receive image information of the coating area to adjust coating parameters.

[0007] According to one embodiment of the present invention, the magnetic encoder is connected to an encoder fixing member.

[0008] According to one embodiment of the present invention, the drive wheel is equipped with a magnet, and the magnetic encoder detects the number of rotations by sensing the magnet.

[0009] According to one embodiment of the present invention, the image transmission visual assistance system includes an image acquisition module and an image processing module, wherein the image acquisition module is connected to the image processing module; The image processing module is configured to: receive target cable image information transmitted by the image acquisition module, identify the outline of the target cable in the target cable image information, and calculate the vertical distance deviation information and / or angle deviation information of the outline relative to the image center.

[0010] According to one embodiment of the present invention, the image acquisition module and the image processing module are both connected to the ground terminal and are used to transmit the image information, vertical distance deviation information and / or angle deviation information of the target cable to the ground terminal for visualization display.

[0011] According to one embodiment of the present invention, the image transmission vision assistance system is integrated on a drone and is used to control the drone to precisely attach the robot platform to the target cable position based on vertical distance deviation information and / or angular deviation information.

[0012] According to one embodiment of the present invention, the bottom of the atomizing spraying device is provided with a brushing mechanism for homogenizing the wet film after spraying.

[0013] This invention also provides an intelligent anti-icing coating method based on vision and encoder feedback. Based on the aforementioned intelligent anti-icing coating system based on vision and encoder feedback, the method includes the following steps: The image transmission vision-assisted system acquires image information of the target cable, identifies the outline of the target cable based on the image information, and calculates the vertical distance deviation and / or angular deviation information of the outline relative to the image center. Based on vertical distance deviation information and / or angular deviation information, the robot platform is precisely attached to the target cable position; The robot platform moves along the target cable and coats the target cable with an atomizing spraying device, transmitting the spraying flow data to the control device. The number of rotations of the drive wheel is monitored by a magnetic encoder, and the walking distance of the robot platform is obtained based on the number of rotations. The walking distance is then transmitted to the control device. Image information of the coated area is collected by a real-time monitoring device and transmitted to the control device. The control device receives spray flow data, travel distance, and image information of the coating area. Based on the spray flow data and travel distance, it calculates the paint consumption and adjusts the coating parameters based on the image information.

[0014] According to one embodiment of the present invention, the vertical distance deviation information and / or angular deviation information of the contour relative to the image center are specifically included in the formula: ; In the formula, Indicates vertical distance deviation; A Indicates the first coefficient. A = k ,in, k Indicates the slope of a straight line; B Indicates the second coefficient. B =1; C Indicates the third coefficient. C = b， in, b Indicates the ordinate intercept; Represents the x-coordinate of the image; The x-coordinate of the geometric center point of the image; m Indicates the center point; Represents the vertical coordinate of the image; The ordinate of the geometric center point of the image; ; In the formula, This indicates the vertical distance angular deviation.

[0015] According to one embodiment of the present invention, the formula for obtaining the walking distance of the robot platform based on the number of rotations specifically includes: ; In the formula, L Indicates the distance traveled; N Indicates the number of rotations; D This indicates the diameter of the drive wheel.

[0016] According to one embodiment of the present invention, the paint consumption is obtained based on spray flow data and travel distance, and the formula specifically includes: ; In the formula, V used Indicates paint consumption; t Indicates the first moment; Indicates the second moment; d Indicates the distance traveled; Indicates the spraying flow rate; j Indicates the current time period.

[0017] According to one embodiment of the present invention, adjusting the coating parameters based on image information of the coating area specifically includes: The actual coverage and actual average gray value are obtained based on the image information of the coated area. When the actual coverage is less than the preset coverage threshold, or the actual average gray value is less than the preset average gray value threshold, increase the spraying flow rate and reduce the walking speed of the robot platform. When the actual coverage rate is greater than the preset coverage rate threshold and the actual average gray value is greater than the preset average gray value threshold, the spraying flow rate is reduced and the walking speed of the robot platform is increased.

[0018] According to one embodiment of the present invention, it further includes: The remaining amount of paint is determined based on the walking distance and spray flow rate data.

[0019] The above technical solution has the following advantages or beneficial effects: Firstly, this invention provides an intelligent anti-icing coating system based on vision and encoder feedback. By integrating a magnetic encoder, a real-time monitoring device, and an image transmission vision assistance system, a closed-loop intelligent coating system from precise attachment to real-time feedback is constructed. The UAV vision assistance system enables automated and precise alignment and attachment of the robot platform, significantly reducing the risks and operational difficulties of high-altitude operations. During the coating process, the magnetic encoder accurately measures the travel distance and combines it with flow data to achieve refined management of paint consumption. The real-time monitoring device directly observes the coating status, enabling operators to dynamically adjust process parameters based on the actual image, completely changing the blindness of traditional open-loop operations. This system significantly improves the uniformity, controllability, and safety of coating operations, achieving high-quality and high-efficiency intelligent operation and maintenance.

[0020] In some embodiments, the magnetic encoder is stably installed by a fixing component to ensure that its relative position with the drive wheel is precise and constant, thereby eliminating measurement errors caused by vibration and displacement and ensuring the long-term reliability and accuracy of the calculation of walking distance and paint consumption.

[0021] In some embodiments, the structure utilizes a non-contact magnetic induction principle for distance measurement, avoiding mechanical wear, improving the encoder's durability and measurement stability in complex outdoor environments, while simplifying installation and maintenance and reducing long-term operating costs.

[0022] In some embodiments, the system integrates an image acquisition and processing module to achieve automated identification and precise positioning of target cables. The image processing module can automatically extract the cable outline from complex backgrounds and accurately calculate its position and angle deviation from the center of the image, transforming the original hanging process that relied on the operator's visual judgment into data-driven precise guidance. This process greatly reduces the operational difficulty and error rate of high-altitude visual hanging, significantly improving the automation level, first-time success rate, and overall operational efficiency of the robot platform's hanging operations, and is especially suitable for operational scenarios with poor visibility or complex environments.

[0023] In some embodiments, this technology provides operators with intuitive and quantitative guidance for attachment by transmitting and displaying visual recognition and computational data back to the ground terminal in real time. Operators no longer need to make difficult spatial judgments based solely on the drone's perspective. Instead, they can remotely and precisely control the drone to make fine-tuning adjustments to its posture based on clear images and accurate deviation data (such as millimeter-level distance and degrees) on the terminal screen. This greatly reduces the reliance on operator experience for high-altitude precision operations, improves the intuitiveness of human-machine interaction and decision-making efficiency, and ensures stable, rapid, and reliable execution of attachment actions in complex environments.

[0024] In some embodiments, this integrated solution enables the UAV itself to become the intelligent attachment execution terminal. The image transmission vision assistance system directly uses the real-time calculated deviation information to the UAV's flight control system, enabling it to automatically or semi-automatically perform closed-loop adjustments of position and attitude. This achieves a leap from "manual image reading operation" to "system autonomous alignment," automating and intelligentizing the attachment process of the robot platform. It significantly reduces manual intervention and operational delays, not only significantly improving the accuracy and success rate of attachment but also further reducing the workload and skill requirements of operators, making the starting point of the entire operation process more reliable and efficient.

[0025] In some embodiments, the brushing mechanism acts directly on the freshly sprayed wet film, effectively eliminating defects such as paint buildup and uneven thickness caused by the paint's own weight flowing or wind disturbance through physical rolling or scraping. This process significantly improves the uniformity, density, and surface smoothness of the coating, thereby enhancing the overall performance and reliability of the anti-icing coating.

[0026] Secondly, this invention provides an intelligent anti-icing coating method based on vision and encoder feedback. This method constructs a complete closed-loop operation process from "intelligent perception" to "precise execution." First, the automated and precise attachment of the robot platform is achieved through a vision-assisted system, solving the initial positioning problem in high-altitude operations. During the coating process, the system simultaneously collects three key data: walking distance, spray flow rate, and visual state of the coating. The control device comprehensively processes this information, not only calculating paint consumption in real time for refined management but also dynamically adjusting spray parameters based on the actual coating appearance. This method transforms the traditional open-loop, experience-dependent coating operation into a data-driven, visually controllable, and intelligent process, greatly improving the quality, efficiency, and safety of the operation.

[0027] In some embodiments, this step enables dynamic closed-loop control based on the actual state of the coating. When the image shows that the coating is too thin or not fully covered, the system can automatically or manually increase the flow rate or decrease the walking speed to reinforce it. Conversely, it can reduce the flow rate or increase the speed to optimize efficiency, ensuring that the coating quality is always under control and significantly improving the coating uniformity and operational adaptability.

[0028] In some embodiments, based on accurately measured walking distance and real-time spraying flow rate, the remaining amount of paint is dynamically calculated and displayed, enabling accurate prediction and management of material resources, avoiding material shortages during operations, and improving the planning and economy of operation and maintenance. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of an intelligent anti-icing coating system based on vision and encoder feedback, as shown in some embodiments of this specification. Figure 2This is a schematic diagram of the atomizing spraying device, real-time monitoring device, and sweeping mechanism shown in some embodiments of this specification; Figure 3 This is a schematic diagram of the magnetic encoder, drive wheel, and encoder fixture structure according to some embodiments of this specification; Figure 4 This is a schematic diagram of the location of the image transmission vision assistance system according to some embodiments of this specification; Figure 5 This is a schematic diagram illustrating the recognition effect of an image transmission visual assistance system according to some embodiments of this specification.

[0030] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 1. Drive control mechanism; 3. Target cable; 4. Guide arm; 5. Lifting mechanism; 6. Guide rail; 7. Image transmission vision auxiliary system; 101. Drive wheel; 102. Magnetic encoder; 103. Encoder fixing part; 201. Atomizing spraying device; 202. Sweeping mechanism; 203. Real-time monitoring device. Detailed Implementation

[0031] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0032] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0033] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0034] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0035] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Example: This invention provides an intelligent anti-icing coating system based on vision and encoder feedback, see [link to relevant documentation]. Figure 1 , Figure 3 and Figure 4 It includes a robot platform, a magnetic encoder 102, an atomizing spraying device 201, a real-time monitoring device 203, an image transmission vision assistance system 7, and a control device. The robot platform is used to walk along the target cable 3. The robot platform is equipped with a drive wheel 101. A magnetic encoder 102 is set on one side of the drive wheel 101 to detect the number of rotations of the drive wheel 101 to calculate the walking distance of the robot platform. An atomizing spraying device 201 is set on the robot platform to spray the anti-icing coating evenly onto the surface of the target cable 3 in a fine mist to achieve efficient coverage. The real-time monitoring device 203 is positioned facing the surface of the target cable 3. The real-time monitoring device 203 is connected to the atomizing spraying device 201 and is located on top of the atomizing spraying device 201. It is used to collect image information of the coating area. The image transmission vision assistance system 7 is used to perform image recognition and positioning of the target cable 3 and output deviation information to guide the robot platform to align with the target cable 3. The control device is set on the robot platform and is communicatively connected to the atomizing spraying device 201, the real-time monitoring device 203 and the magnetic encoder 102. It is used to receive travel distance and spraying flow data to calculate paint consumption and receive image information of the coating area to adjust coating parameters.

[0038] In some embodiments, the magnetic encoder 102 is connected to an encoder fixture 103.

[0039] In some embodiments, the drive wheel 101 is equipped with a magnet, and the magnetic encoder 102 detects the number of rotations by sensing the magnet. During the rotation of the drive wheel 101, the magnetic encoder 102 can sense the magnet on the drive wheel 101 to read the number of rotations of the drive wheel within a certain period of time. Combined with the diameter of the drive wheel, the walking speed and walking distance of the robot platform can be accurately calculated. Combined with the known real-time spraying flow rate, the system can dynamically estimate the remaining paint capacity in the water tank and feed it back to the ground operating system to provide data support for operation scheduling.

[0040] In some embodiments, the magnetic encoder 102 is an AS5600 magnetic encoder, and the value of 0~4096 is read directly through IIC as one revolution.

[0041] In some embodiments, in addition to the magnetic encoder 102, optical encoders, inertial navigation or visual odometry can also be used to measure walking distance.

[0042] In some embodiments, the image transmission visual assistance system 7 includes an image acquisition module and an image processing module, with the image acquisition module connected to the image processing module; the image processing module is configured to receive image information of the target cable 3 transmitted by the image acquisition module, see [link to documentation]. Figure 5 The outline of target cable 3 in the image information of target cable 3 is identified, and the vertical distance deviation information and / or angular deviation information of the outline relative to the image center are calculated.

[0043] In some embodiments, the image acquisition module and the image processing module are both connected to the ground terminal and are used to transmit the image information, vertical distance deviation information and / or angle deviation information of the target cable 3 to the ground terminal for visualization display.

[0044] In some embodiments, the image transmission vision assistance system 7 is integrated on the UAV to improve the accuracy and automation level of UAV hoisting operations, and to control the UAV to accurately attach the robot platform to the target cable 3 position by transmitting vertical distance deviation information and / or angular deviation information.

[0045] In some embodiments, the image transmission vision assistance system 7 includes a high-definition camera (image acquisition module) and an image processing module, used to identify and locate the target cable 3 in real time before hoisting. The image transmission vision assistance system 7 can automatically detect and mark the outline of the target cable 3, and calculate the vertical distance deviation and angular deviation of the target cable 3 relative to the center of the image based on the center coordinates of the image pixels. The operator or flight control system can use this real-time feedback information to accurately adjust the position and attitude of the UAV, ensuring that the cable tray of the robot platform can be accurately aligned and hooked onto the target cable 3, significantly reducing the difficulty and error rate of manual visual hooking.

[0046] In some embodiments, the image transmission visual assistance system 7 may be of the model SIYI A8-mini, Nuwa-HP6OC, or ORBBEC Gemini215.

[0047] In some embodiments, there are two atomizing spraying devices 201, which are respectively disposed on both sides of the robot platform.

[0048] In some embodiments, the bottom of the atomizing spraying device 201 is provided with a brushing mechanism 202 for homogenizing the wet film after spraying.

[0049] In some embodiments, the brushing mechanism 202 consists of a pair of elastically pressed metal brush rollers mounted on a motor-driven rotating shaft. During operation, it rotates at high speed and physically rolls and homogenizes the freshly sprayed wet film, effectively eliminating flow and accumulation, and ensuring a uniform coating thickness and a dense and smooth surface. The real-time monitoring device 203 is installed above the brushing mechanism 202.

[0050] In some embodiments, a flexible silicone scraper, a vibratory smoothing device, or an electrostatic adsorption homogenizer can be used instead of a brush roller, which is suitable for coatings of different viscosities.

[0051] In some embodiments, the real-time monitoring device 203 includes a high-definition camera and an auxiliary lighting source. The lens faces the surface of the target cable 3, forming a visual monitoring area facing the area being processed. The real-time monitoring device 203 can also transmit the image to the ground control terminal through a wireless communication module. Operators can visually observe the coating status on the ground, including the integrity of the coverage, the uniformity of the thickness, and whether there are defects such as missed coating or bubbles.

[0052] In some embodiments, in addition to a visible light camera, an infrared thermal imaging, laser ranging, or ultrasonic thickness sensor may be integrated to achieve non-contact quantitative detection of coating thickness.

[0053] In some embodiments, the robot platform includes a drive control mechanism 1, a guide arm 4, a hoisting mechanism 5, and a guide channel 6; the guide channel 6 is disposed at the lower end of the drive control mechanism 1, the guide arm 4 is disposed at the lower end of the guide channel 6, the hoisting mechanism 5 is disposed on the drive control mechanism 1, and an atomizing spraying device 201 is connected to a set of opposite sidewalls of the drive control mechanism 1 and is connected to the drive control mechanism 1; the drive wheel 101 is located on the drive control mechanism 1.

[0054] In some embodiments, the robot platform has an inverted Y-shaped structure, straddling the target cable 3. The atomizing spraying device 201 completes the coating work on the target cable 3. There are two target cables 3 at the front and two at the back. The atomizing nozzles spray the coating through the internal circuit. The guide arm 4 and the guide channel 6 are combined to form a Y-shaped structure. During the operation, it is connected to the UAV through the hoisting mechanism 5. When the whole is loaded onto the target cable 3, the target cable 3 first touches the guide arm 4 and slides into the middle guide channel 6 along the direction of the guide arm 4. The distance in the middle of the guide channel 6 is adapted to the target cable 3.

[0055] In some embodiments, the drive control mechanism 1 includes a drive component, a fluid control component, and a main housing. The drive component is disposed on the lower wall of the main housing, and the fluid control component is disposed inside the main housing. The drive component is used to control the device to move along the extension direction of the target cable 3. One end of the fluid control component is connected to a water tank and the other end is connected to an atomizing spraying device 201. The fluid control component is used to control the two atomizing spraying devices 201 to work alternately, with one atomizing spraying device 201 performing a cleaning operation and the other atomizing spraying device 201 performing a spraying operation.

[0056] In some embodiments, the fluid control component includes a peristaltic pump and a solenoid valve. One end of the peristaltic pump is connected to a water tank and the other end is connected to the solenoid valve. The solenoid valve is connected to the atomizing spraying device 201 through a water pipe. By energizing and de-energizing the solenoid valve, the paint in the water tank flows into different atomizing spraying devices 201.

[0057] In some embodiments, the fluid control assembly further includes a tee connector with two water tanks, one connector of the tee connector being connected to one water tank, another connector being connected to the other water tank, and the remaining connector being connected to a peristaltic pump.

[0058] In some embodiments, two guide channels and two guide arms are provided, with the two guide channels spaced apart and the distance between the two guide arms gradually increasing from the end closer to the guide channel to the end farther from the guide channel. Each guide arm is provided with a water tank.

[0059] In some embodiments, the guide channel includes a guide housing and a support assembly. The support assembly is disposed inside the guide housing. The support assembly includes an electric push rod and a support concave wheel. The electric push rod is disposed on the inner wall of the guide arm. The output end of the electric push rod is connected to the support concave wheel. The support concave wheel abuts against the target cable 3.

[0060] In some embodiments, the guide arm includes a guide housing, a water tank is disposed inside the guide housing, a recessed space is provided inside the water tank, and an electric push rod is disposed within the recessed space.

[0061] In some embodiments, the drive control mechanism includes a drive component, a fluid control component, and a main housing. The drive component is disposed on the main housing, and the fluid control component is disposed inside the main housing. One end of the fluid control component is connected to a water tank, and the other end is connected to the atomizing spraying device 201. The drive component is used to drive the de-icing device to move along the cable.

[0062] In some embodiments, the drive assembly includes a main control board, a geared motor, and drive wheels 101. The main control board and geared motor are both located inside the main body housing. The lower end of the drive wheel 101 passes through the main body housing and contacts the target cable 3. Two geared motors and two drive wheels are provided. The geared motors are right-angle geared motors. Each geared motor is controlled to be switched on and off by the main control board. The output end of the geared motor is rigidly connected to the corresponding drive wheel 101. The two drive wheels 101 are distributed at both ends of the movement direction, which is the extension direction of the target cable 3. The lower wall of the main body housing has two openings. The lower ends of the drive wheels 101 extend out of the corresponding openings and contact the target cable 3. The main control board controls the geared motors to start, driving the two drive wheels 101 to rotate in the same direction, and then driving the entire device to move along the extension direction of the target cable 3.

[0063] In some embodiments, the hoisting mechanism includes a connector, a fixed shaft, and a hanging ring. The connector is fixed to the upper wall of the drive control mechanism, the fixed shaft is fixed inside the connector, and the hanging ring is connected to the fixed shaft.

[0064] This system is not only suitable for anti-icing coating, but also for various cable surface functionalization treatments such as anti-corrosion coating, fireproof coating, and conductive coating. It can also be adapted to linear structures such as pipes and rails.

[0065] This system achieves closed-loop control from application to quality verification through a collaborative process of "spraying - brushing - image transmission". Operators can dynamically adjust parameters such as spraying flow rate and walking speed based on real-time images and paint balance information to ensure high-quality, high-efficiency and high-reliability anti-icing coating.

[0066] This invention employs a sequential design of spraying followed by brushing, resulting in a rational structure that balances efficiency and uniformity, effectively overcoming coating defects caused by single-coating methods. A real-time monitoring device 203 enables visual monitoring of the coating status. Operators can dynamically adjust process parameters (such as output and travel speed) based on real-time images, forming a closed loop of "perception-decision-execution," significantly improving coating reliability. A magnetic encoder 102 monitors the rotation of the drive wheel 101, and combined with the wheel diameter, calculates the travel distance, thereby estimating paint consumption and achieving refined resource management. The image transmission vision assistance system 7 mounted on the UAV performs real-time identification and contour marking of the target cable 3, calculating its distance and angular deviation relative to the image center, providing crucial guidance information for precise cable placement on the robot platform, significantly improving the level of automation and success rate of the operation.

[0067] This invention also provides an intelligent anti-icing coating method based on vision and encoder feedback, comprising the following steps: Step 1: The image transmission vision assistance system 7 acquires image information of the target cable 3, preprocesses the image information of the target cable 3 (grayscale conversion, contrast enhancement), identifies the contour of the target cable 3 based on the preprocessed image information, and calculates the vertical distance deviation information and / or angular deviation information of the contour relative to the image center (calculating the percentage of pixels covered by the coating, coverage rate). ).

[0068] In some embodiments, the image may also be referred to as a grayscale image, which will not be repeated hereafter.

[0069] In some embodiments, step 1 specifically includes: Step 1.1, Image Acquisition and Preprocessing: The real-time monitoring device 203 acquires the original grayscale image containing the target cable 3. The resolution is Pixels. The following preprocessing operations are then performed: Gaussian filtering: using a standard deviation of of The Gaussian kernel is used to smooth the image and suppress noise.

[0070] Adaptive thresholding: The image is binarized using a local mean adaptive thresholding method (such as the Sauvola algorithm) to obtain a binary image. The foreground (cable) pixel value is 255, and the background pixel value is 0.

[0071] Step 1.2, Contour Extraction and Filtering: For binary images Contour detection is performed to obtain the boundary point set of all connected components. Based on the contour shape and area threshold, the main contour most likely corresponding to target cable 3 is selected. D : ; in, Represents the x-coordinate of the image; Represents the vertical coordinate of the image; Indicates the total number of contour points. i Indicates an index; This represents the set of points representing the outline of the target cable.

[0072] Step 1.3, Line Fitting: Applying the selected contour point set... The least squares method is used to fit the line and solve for the optimal line parameters. Let the slope-intercept form of the fitted line be: ; In the formula, k Indicates the slope of a straight line; b Indicates the ordinate intercept; To facilitate subsequent calculations, the slope-intercept form equation is converted into the general form equation: Ax + By + C =0; In the formula, A Indicates the first coefficient. A = k ,in, k Indicates the slope of a straight line; B Indicates the second coefficient. B =1; C Indicates the third coefficient. C = b， in, b This represents the intercept of the ordinate axis.

[0073] Step 1.4, Deviation Calculation: The vertical distance deviation information and / or angular deviation information of the contour relative to the image center, for the vertical distance deviation ( The geometric center point coordinates of the image are: ; In the formula, Represents the x-coordinate of the image; The x-coordinate of the geometric center point of the image; m Indicates the center point; Represents the vertical coordinate of the image; The ordinate of the geometric center point of the image; Indicates the image width; Indicates the image height; Fitted straight line to center point The vertical distance is the vertical distance deviation. : ; In the formula, Indicates vertical distance deviation; A Indicates the first coefficient. A = k ,in, k Indicates the slope of a straight line; B Indicates the second coefficient. B =1; C Indicates the third coefficient. C = b， in, b Indicates the ordinate intercept; Represents the x-coordinate of the image; The x-coordinate of the geometric center point of the image; m Indicates the center point; Represents the vertical coordinate of the image; The vertical coordinate represents the geometric center point of the image.

[0074] For angle deviation ( The angle between the fitted line and the X-axis of the image. , by slope The calculation shows that: ; In the formula, Indicates the vertical distance angular deviation; Under ideal splicing conditions, the target cable should be parallel to the horizontal axis of the image, i.e., the desired angle is 0°. Therefore, the angle deviation Δ θ = α 0= α .

[0075] Step 2: Based on the vertical distance deviation information and / or angular deviation information, precisely attach the robot platform to the target cable 3 position. The adjustment logic is as follows: When the coating is thin and has low coverage: Increase flow Or reduce speed ; When the coating is too thick and drips: Reduce flow Or increase speed ; in, and The preset empirical value can be determined through calibration experiments.

[0076] Step 3: The robot platform moves along the target cable 3 and coats the target cable 3 with the atomizing spraying device 201, transmitting the spraying flow data to the control device.

[0077] Step 4: Monitor the number of rotations of the drive wheel 101 using the magnetic encoder 102, obtain the walking distance of the robot platform based on the number of rotations, and transmit the walking distance to the control device. In some embodiments, the walking distance of the robot platform is obtained based on the number of rotations. The calculation method specifically includes: obtaining the number of rotations of the drive wheel 101 through a magnetic encoder. N Given the diameter of drive wheel 101 D The circumference of a single loop is The cumulative walking distance L The calculation formula is: .

[0078] Step 5: Collect image information of the coated area through the real-time monitoring device 203 and transmit the image information of the coated area to the control device.

[0079] Step 6: The control device receives spray flow data, travel distance, and image information of the coating area. Based on the spray flow data and travel distance, it obtains the paint consumption and adjusts the coating parameters based on the image information.

[0080] In some embodiments, the method further includes: determining the remaining amount of paint based on walking distance and spray flow rate data.

[0081] In some embodiments, paint consumption is obtained based on spray flow rate data and travel distance. The calculation method specifically includes: controlling the spray flow rate using a constant flow pump and a PWM signal, and determining the spray flow rate per unit time. (Unit: mL / s) Can be read in real time, from the beginning to the first moment. Paint consumption V used ( t )for: ; In the formula, V used Indicates paint consumption; t Indicates the first moment; Indicates the second moment; d Indicates the distance traveled; Indicates the spraying flow rate; j Indicates the current time period.

[0082] In some embodiments, the walking speed is calculated using a sliding window method, with a sampling period of 1 / 2π. ,recent The increase in walking distance within each cycle is Then the current speed v ( t Approximately: .

[0083] In some embodiments, adjusting the coating parameters based on image information specifically includes: The actual coverage and actual average gray value are obtained based on the image information of the coated area. When the actual coverage is less than the preset coverage threshold, or the actual average gray value is less than the preset average gray value threshold, increase the spraying flow rate and reduce the walking speed of the robot platform.

[0084] In some embodiments, step 6 specifically includes: The control device receives image information of the coated area transmitted back by the real-time monitoring device 203, performs image processing on the coated area image information, and quantitatively evaluates the uniformity and integrity of the current coating. Key evaluation indicators include: actual coverage. The percentage of pixels in the coated area out of the total target area pixels. Actual average grayscale value. The actual average pixel intensity of the coated area, used to indirectly reflect the coating thickness.

[0085] Preset coverage and preset average gray value The ideal target range. The results calculated in real time. and Compare with the target value and determine the adjustment strategy based on the magnitude of the deviation.

[0086] Based on the comparison results, the following rules are used for dynamic adjustment: When the coating is too thin or does not cover completely, i.e. or At the same time, increase the spraying flow rate and reduce the walking speed of the robot platform. The specific adjustment formula can be expressed as: ; ; In the formula, This indicates the new spray flow rate setting; This indicates the current spray flow rate setting. and This represents a set of preset adjustment coefficients of different proportions, used to convert image deviation into specific flow or speed adjustment amounts, which can be determined through on-site calibration experiments; This indicates the new device walking speed setting; This indicates the current device walking speed setting.

[0087] When the coating is too thick, it may drip or accumulate. and At the same time, reduce the spraying flow rate and increase the walking speed of the robot platform. The specific adjustment formula can be expressed as:

[0088]

[0089] in, and For another set of preset adjustment coefficients of different proportions.

[0090] The structure and working principle of the present invention will be further explained below: In some embodiments of this specification, the intelligent anti-icing coating system based on vision and encoder feedback is implemented as follows: Before the operation begins, the operator controls a drone equipped with the image transmission vision assistance system 7 of this invention to fly to the vicinity of the target cable 3; the image transmission vision assistance system 7 on the drone is activated, and the image transmission vision assistance system 7 automatically identifies the target cable 3 and displays deviation information. The operator then fine-tunes the position of the drone until the cable tray of the robot platform is precisely aligned with the target cable 3, and then performs the descent and splicing action. After the splicing is completed, the robot platform begins to move autonomously and execute the aforementioned closed-loop operation process of spraying-sweeping-monitoring.

[0091] During the movement along the target cable 3, the atomizing spraying device 201 at the front end of the robot platform first sprays the anti-icing coating evenly onto the surface of the target cable 3 at a preset flow rate. Following this is a pair of elastically pressed rotating brush rollers 202, driven by a micro-motor, which instantly roll and homogenize the freshly sprayed wet film, effectively eliminating defects such as flow and accumulation caused by gravity or wind, ensuring a dense and uniform coating. Simultaneously, the real-time monitoring device 203 is aligned with the surface of the target cable 3, transmitting images or video streams to the operator's tablet or control console via the image transmission vision assistance system 7. Furthermore, the magnetic encoder 102 records the walking distance in real time, and the control system calculates the coating consumption accordingly, displaying the remaining capacity on the ground terminal. The operator can intuitively judge the current coating quality based on the screen: if a section of the coating is found to be too thin or incompletely covered, the robot platform's walking speed can be immediately reduced or the spraying flow rate increased via remote control commands; conversely, the walking speed can be appropriately increased or the output reduced, achieving dynamic closed-loop adjustment.

[0092] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the above embodiments should be considered exemplary rather than restrictive in all respects; the scope of protection of the present invention is defined by the appended claims, not by the foregoing description, and thus all changes falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0093] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity; those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art. The above content is merely illustrative of the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solutions based on the technical concept proposed in this invention fall within the scope of protection of the claims of this invention.

Claims

1. A smart anti-icing coating system based on vision and encoder feedback, characterized in that, include: A robot platform, wherein a drive wheel (101) is provided on the robot platform for walking along the target cable (3); A magnetic encoder (102) is installed on one side of the drive wheel (101) to detect the number of rotations of the drive wheel (101) in order to calculate the walking distance of the robot platform; Atomizing spraying device (201) is set on a robot platform for spraying anti-icing coating onto the surface of the target cable (3); A real-time monitoring device (203) is set facing the surface of the target cable (3). The real-time monitoring device (203) is connected to the atomizing spraying device (201) and is located on top of the atomizing spraying device (201) for collecting image information of the coating area. The image transmission vision assistance system (7) is used to perform image recognition and positioning of the target cable (3) and output deviation information to guide the robot platform to align with the target cable (3); The control device is set on the robot platform and is connected in communication with the atomizing spraying device (201), the real-time monitoring device (203) and the magnetic encoder (102). It is used to receive walking distance and spraying flow data to calculate paint consumption, and to receive image information of the coating area to adjust coating parameters.

2. The intelligent anti-icing coating system based on vision and encoder feedback according to claim 1, characterized in that, The drive wheel (101) is equipped with a magnet, and the magnetic encoder (102) detects the number of rotations by sensing the magnet.

3. The intelligent anti-icing coating system based on vision and encoder feedback according to claim 1, characterized in that, The image transmission visual assistance system (7) includes an image acquisition module and an image processing module, and the image acquisition module is connected to the image processing module; The image processing module is configured to: receive the target cable (3) image information transmitted by the image acquisition module, identify the outline of the target cable (3) in the target cable (3) image information, and calculate the vertical distance deviation information and / or angle deviation information of the outline relative to the image center.

4. The intelligent anti-icing coating system based on vision and encoder feedback according to claim 3, characterized in that, The image acquisition module and the image processing module are both connected to the ground terminal and are used to transmit the image information, vertical distance deviation information and / or angle deviation information of the target cable (3) to the ground terminal for visualization display.

5. The intelligent anti-icing coating system based on vision and encoder feedback according to claim 4, characterized in that, The image transmission vision assistance system (7) is integrated on the UAV and is used to control the UAV to accurately attach the robot platform to the target cable (3) position based on the vertical distance deviation information and / or angle deviation information.

6. A smart anti-icing coating method based on vision and encoder feedback, characterized in that, The intelligent anti-icing coating system based on vision and encoder feedback according to any one of claims 1-5 includes the following steps: The image transmission vision assistance system (7) acquires image information of the target cable (3), identifies the outline of the target cable (3) based on the image information of the target cable (3), and calculates the vertical distance deviation information and / or angle deviation information of the outline relative to the image center. Based on the vertical distance deviation information and / or angular deviation information, the robot platform is precisely attached to the target cable (3) position; The robot platform moves along the target cable (3), coats the target cable (3) with atomizing spraying device (201), and transmits the spraying flow data to the control device; The number of rotations of the drive wheel (101) is monitored by the magnetic encoder (102), and the walking distance of the robot platform is obtained based on the number of rotations. The walking distance is then transmitted to the control device. Image information of the coated area is collected by the real-time monitoring device (203) and transmitted to the control device. The control device receives spray flow data, travel distance, and image information of the coating area. Based on the spray flow data and travel distance, it calculates the paint consumption and adjusts the coating parameters based on the image information.

7. The intelligent anti-icing coating method based on vision and encoder feedback according to claim 6, characterized in that, The formula specifically includes the vertical distance deviation information and / or angular deviation information of the contour relative to the image center: ； In the formula, Indicates vertical distance deviation; A Indicates the first coefficient. A = k ,in, k Indicates the slope of a straight line; B Indicates the second coefficient. B =1; C Indicates the third coefficient. C = b， in, b Indicates the ordinate intercept; Represents the x-coordinate of the image; The x-coordinate of the geometric center point of the image; m Indicates the center point; Represents the vertical coordinate of the image; The ordinate of the geometric center point of the image; ； In the formula, This indicates the vertical distance angular deviation.

8. The intelligent anti-icing coating method based on vision and encoder feedback according to claim 6, characterized in that, The formula for calculating the robot platform's walking distance based on the number of rotations specifically includes: ； In the formula, L Indicates the distance traveled; N Indicates the number of rotations; D This indicates the diameter of the drive wheel (101).

9. The intelligent anti-icing coating method based on vision and encoder feedback according to claim 6, characterized in that, The formula for calculating paint consumption based on spray flow rate data and travel distance specifically includes: ； In the formula, V used Indicates paint consumption; t Indicates the first moment; Indicates the second moment; d Indicates the distance traveled; Indicates the spraying flow rate; j Indicates the current time period.

10. The intelligent anti-icing coating method based on vision and encoder feedback according to claim 6, characterized in that, The adjustment of coating parameters based on image information specifically includes: The actual coverage and actual average gray value are obtained based on the image information of the coated area. When the actual coverage is less than the preset coverage threshold, or the actual average gray value is less than the preset average gray value threshold, increase the spraying flow rate and reduce the walking speed of the robot platform. When the actual coverage rate is greater than the preset coverage rate threshold and the actual average gray value is greater than the preset average gray value threshold, the spraying flow rate is reduced and the walking speed of the robot platform is increased.

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