Power plant gate multi-region adaptive automatic sand blasting system

Abstract

The present application relates to the technical field of power plant maintenance, and more particularly to a power plant gate multi-region adaptive automatic sandblasting system, comprising a handheld sandblasting gun execution module, a moving speed and posture sensing module, a three-dimensional displacement tracking module, a sandblasting medium supply and regulation module, a central control module and an interactive feedback module. The moving speed and posture sensing module collects the moving speed of the operator in real time and uses it as a control signal to achieve intelligent adjustment, which can realize real-time adaptive adjustment of sandblasting parameters, avoid over-spraying and abrasive waste in areas that have reached the standard, and ensure sufficient rust removal in heavy rust areas, significantly improving work efficiency and economy.

Description

Technical Field

[0001] This invention relates to the field of power plant maintenance technology, and in particular to an automatic sandblasting system for power plant gates that adapts to multiple areas. Background Technology

[0002] Metal gates at hydropower stations are critical facilities in water conservancy projects. Being constantly submerged or in humid environments, their surfaces are highly susceptible to corrosion. To ensure normal operation and extend their service life, regular sandblasting is necessary to remove rust and achieve the required cleanliness level. During sandblasting, operators naturally convey their intentions through the speed at which they move the spray gun. Rapid movement indicates that the area has been cleaned or has only minor rust, while slow movement indicates more severe rust requiring more intensive treatment. However, traditional equipment cannot recognize and utilize this instinctive signal for intelligent adjustment.

[0003] Currently, manual operation with handheld sandblasting guns suffers from severe issues of parameter adjustment lag and waste. Operators rely entirely on personal experience to manually adjust sandblasting pressure and flow rate when working in different areas, unable to automatically match sandblasting parameters based on real-time movement speed. This results in continuous high-pressure, high-flow-rate blasting in areas that already meet standards, causing significant abrasive waste and over-blasting damage to the base material. In heavily rusted areas, the failure to adjust parameters in time leads to incomplete rust removal, requiring repeated re-blasting. Furthermore, the complex structure of gates, with varying sandblasting parameter requirements for different areas such as the plane, beam sides, beam bottom, sealing surfaces, and welds, presents significant delays in manual identification and adjustment, failing to achieve real-time adaptiveness and severely impacting operational efficiency and economy.

[0004] Therefore, there is an urgent need for an intelligent sandblasting system that can sense the operator's movement speed in real time and automatically adjust the sandblasting parameters accordingly. This system can transform the operator's instinctive actions into control signals, enabling adaptive adjustment of speed and sandblasting parameters that are negatively correlated. This avoids over-spraying waste in areas that have already met the standards, while ensuring thorough rust removal in heavily rusted areas. As a result, it can systematically improve work efficiency, reduce abrasive consumption, and ensure consistent rust removal quality. Summary of the Invention

[0005] To achieve the above objectives, this invention proposes an automatic sandblasting system for multi-area adaptation of power plant gates, including a handheld sandblasting gun execution module, a movement speed and attitude sensing module, a three-dimensional displacement tracking module, a sandblasting medium supply and control module, a central control module, and an interactive feedback module.

[0006] A handheld sandblasting gun execution module includes a handheld sandblasting gun for spraying abrasive onto the surface of a gate;

[0007] The movement speed and attitude sensing module is used to collect the operator's movement speed and the pitch and roll angles of the spray gun in real time.

[0008] The three-dimensional displacement tracking module is used to construct the motion trajectory of the spray gun in the three-dimensional space of the gate in real time;

[0009] The sandblasting medium supply and control module includes an electric pressure regulating valve and an electric sand regulating valve, which are used to regulate the sandblasting pressure and flow rate;

[0010] The central control module is connected to the movement speed and attitude perception module, the three-dimensional displacement tracking module, and the sandblasting medium supply and control module. The central control module is configured to determine the reference pressure and reference flow rate based on the real-time movement speed detected by the movement speed and attitude perception module, according to the speed negative correlation adjustment strategy of the faster the speed, the smaller the sandblasting parameter, and the slower the speed, the larger the sandblasting parameter. Based on the pitch angle and roll angle, the module determines the gate area type corresponding to the current operation in real time and corrects the parameters of the reference pressure and reference flow rate. The gate area type includes the beam grid side, beam grid bottom, sealing surface, and weld. When the instantaneous speed exceeds the preset safety threshold and the duration exceeds the preset time, it is determined that the sandblasting gun has been accidentally released and an emergency shutdown is triggered.

[0011] The interactive feedback module, connected to the central control module, is used to provide feedback on the current working status to the operators.

[0012] In one example, the movement speed and attitude sensing module reuses data from a six-axis inertial measurement unit (IMU), and detects movement speed through acceleration integration and zero-speed correction. The speed detection method involves converting the triaxial acceleration measured by the accelerometer to the workpiece surface coordinate system based on the calculated pitch and roll angles, and extracting the acceleration component along the movement direction of the gate plane. The real-time velocity is obtained by integrating the acceleration component over time, and the calculation formula is as follows: In the formula, for Real-time speed at any moment The velocity at the previous moment, The acceleration component is along the direction of movement in the gate plane. For the sampling time interval, when the spray gun is detected to be stationary or the operator releases the trigger, a zero-speed correction is performed, resetting the speed integral state to zero.

[0013] In one example, the speed-negative correlation adjustment strategy categorizes real-time movement speed into extremely slow, slow, medium, and fast speeds. As the speed changes continuously, pressure and flow are calculated as baseline values ​​using linear interpolation, with the interpolation formula being: , In the formula, , These are the reference pressure and reference flow rate, respectively. These represent the pressure values ​​corresponding to the lower and higher ends of the speed range, respectively. These are the corresponding flow rates. At the current speed, These represent the lower and upper boundary values ​​of the speed range, respectively.

[0014] In one example, the central control module is configured to perform attitude region identification and parameter correction according to the following rules:

[0015] When the absolute value of the roll angle is greater than 45° and lasts for more than 0.5 seconds, and the current moving speed is not in the fast setting, it is judged as the side of the beam grid, with a pressure correction factor of 0.60 and a flow correction factor of 0.70.

[0016] When the pitch angle is less than -20° and lasts for more than 0.5 seconds, it is determined to be the bottom surface of the beam grid, with a pressure correction factor of 1.20 and a flow correction factor of 1.10.

[0017] When the absolute values ​​of both pitch and roll angles are less than 15°, and the current speed setting is extremely slow or slow, it is determined to be a sealing surface, and the upper limit of pressure is forcibly limited to 0.5MPa and the upper limit of flow rate is 4kg / min.

[0018] When the pitch or roll angle fluctuates within ±10° at a frequency exceeding 2Hz, it is determined to be a weld area. The original pressure and flow rate are maintained, and the correction factor is 1.0.

[0019] When the absolute value of the pitch angle is greater than 60° or the absolute value of the roll angle is greater than 70° and the duration exceeds 0.3 seconds, it is determined to be a dangerous posture, and the pressure is forcibly reduced to below 0.1MPa and the sand flow is shut off.

[0020] In one example, in the release safety protection, the safety threshold is set to 800 mm / s by default, and the preset time is 20 ms. When the emergency shutdown is triggered, the central control module sends a shutdown signal to the quick-cut-off valve in the sandblasting medium supply and control module within 5 ms. At the same time, the target pressure of the electric pressure regulating valve is set to 0 and the opening of the electric sand regulating valve is set to 0, ensuring that the compressed air and sand supply are completely cut off within 50 ms. After the release protection is triggered, the system enters the locked state.

[0021] In one example, the central control module records the instantaneous flow rate of the electric sand regulating valve in real time and calculates the instantaneous coverage area of ​​the spray gun on the gate surface. The calculation formulas for the length L of the coverage area along the movement direction and the width W perpendicular to the movement direction are as follows: In the formula, The vertical distance from the spray gun to the gate surface is measured using an added miniature laser rangefinder sensor. The spray angle is half-angle (default 15°, total spray angle 30°). Instantaneous movement speed The sampling time interval;

[0022] The formula for calculating the instantaneous coverage area is: The formula for calculating the sand density per unit time is: The amount of sandblasting at this location is determined by combining the sandblasting dwell time. for .

[0023] In one example, the central control module also includes a self-learning optimization closed loop, where each sandblasting operation is treated as a complete data sample, automatically collecting the operation ID, timestamp, gate type, operator ID, speed time series, attitude angle series, displacement trajectory, pressure and flow commands output at each moment, cumulative sand output and residence time of each grid, whether the hand-off protection is triggered, and the final rust removal quality inspection results.

[0024] In one example, the interactive feedback module includes a multi-color indicator light mounted on the tail of the sandblasting gun handle and a vibration motor embedded in the handle. The central control module controls the output of the indicator light and the vibration motor according to the currently identified working mode: flat / normal mode corresponds to solid green; fast removal corresponds to slow flashing green; beam grid side mode corresponds to slow flashing yellow and slow continuous vibration; beam grid bottom mode corresponds to fast flashing yellow and fast continuous vibration; sealing surface protection mode corresponds to solid blue and very light intermittent vibration; weld seam mode corresponds to white breathing light and intermittent vibration; and dangerous posture or drop protection corresponds to red strobe light, continuous strong vibration, and buzzer alarm.

[0025] The automatic sandblasting system for power station gates with multi-zone adaptability proposed in this invention can bring the following beneficial effects:

[0026] 1. This invention uses a movement speed and posture sensing module to collect the operator's movement speed in real time and uses it as a control signal to achieve intelligent adjustment. When the operator moves the spray gun quickly in a certain area, it indicates that the rust removal in that area is complete or the rust is light, and the system automatically reduces the sandblasting pressure and flow rate. When the operator slows down, it indicates that the rust in that area is heavy or requires fine treatment, and the system automatically increases the sandblasting pressure and flow rate. This speed-negative adjustment strategy based on the operator's instinctive movements can achieve real-time adaptive adjustment of sandblasting parameters without additional operation or preset programs. It avoids over-spraying and abrasive waste in areas that have already met the standards, and ensures sufficient rust removal in heavily rusted areas, significantly improving work efficiency and economy.

[0027] 2. This invention achieves digital recording and quality traceability of the entire sandblasting process through a three-dimensional displacement tracking module and a sand output accumulation algorithm. The system constructs the real-time trajectory of the spray gun in the three-dimensional space of the gate, divides the gate surface into grid cells, accurately records the cumulative sand output and residence time of each grid, and generates a visualized three-dimensional rust distribution heat map. This heat map intuitively displays the degree of rust and sandblasting coverage in each area, providing quality inspectors with precise guidance for re-blasting and avoiding the blindness of relying on experience-based judgment in traditional operations. Attached Figure Description

[0028] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention. In the drawings:

[0029] Figure 1 This is a schematic diagram of the system architecture of an automatic sandblasting system that adapts to multiple areas of a power station gate. Detailed Implementation

[0030] To more clearly illustrate the overall concept of the present invention, a detailed description will be provided below with reference to the accompanying drawings and examples.

[0031] In the description of this invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0032] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0033] 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.

[0034] In this invention, unless otherwise expressly specified and limited, the first feature "on" or "below" the second feature may be in direct contact with the first and second features, or indirect contact through an intermediate medium. In the description of this specification, references to terms such as "an embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0035] like Figure 1 As shown, this invention proposes an automatic sandblasting system for power plant gates that adapts to multiple areas, including a handheld sandblasting gun execution module, a movement speed and attitude sensing module, a three-dimensional displacement tracking module, a sandblasting medium supply and control module, a central control module, and an interactive feedback module. The modules work together to form an intelligent closed loop.

[0036] The handheld sandblasting gun execution module is the working terminal of the entire system. It includes a handheld sandblasting gun, which is used to spray abrasive to remove rust from the gate surface. The sandblasting gun body has reserved installation interfaces for sensors and actuators. The handle integrates a six-axis inertial measurement unit. The handle tail is equipped with a multi-color indicator light and an eccentric wheel vibration motor. The air and sand circuit interfaces are connected to the media supply and control module through wear-resistant hoses.

[0037] The movement speed and attitude sensing module acquires the operator's intentions and the spatial state of the spray gun in real time using a completely non-contact method. This module reuses data from a six-axis, six-inertial measurement unit, and detects movement speed through acceleration integration and zero-speed correction. At the same time, it calculates the pitch and roll angles of the spray gun through complementary filtering or extended Kalman filtering.

[0038] The specific speed detection method is as follows: based on the pitch and roll angles output by the attitude module, the triaxial acceleration measured by the accelerometer is transformed to the workpiece surface coordinate system, and the acceleration component along the movement direction of the gate plane is extracted. The real-time velocity is obtained by integrating the acceleration component over time, and the calculation formula is as follows:

[0039] In the formula, for Real-time speed at any moment The velocity at the previous moment, The acceleration component is along the direction of movement in the gate plane. The sampling time interval,

[0040] When the spray gun is detected to be stationary or the operator releases the trigger, zero-speed correction is performed, resetting the speed integral state to zero to eliminate integral drift. The integral speed is divided into four levels after passing through a first-order low-pass filter with a time constant of 0.2s: extremely slow (0~30mm / s), slow (30~70mm / s), medium (70~120mm / s), and fast (>120mm / s). These levels can be manually set as needed.

[0041] Meanwhile, the module monitors the instantaneous speed value in real time and sets a safety threshold for release. Once the instantaneous speed exceeds the threshold and the duration exceeds 20ms, the system immediately determines that the sandblasting gun has been accidentally released and triggers an emergency shutdown.

[0042] The three-dimensional displacement tracking module is responsible for constructing the motion trajectory of the spray gun in the three-dimensional space of the gate in real time. This module uses the accelerometer in the six-axis inertial measurement unit to perform double integration to obtain the relative displacement, and at the same time combines the pitch angle and roll angle to decompose the displacement into the horizontal direction (X), vertical direction (Y) and depth direction (Z) of the gate.

[0043] Displacement calculation employs a strapdown inertial navigation algorithm. First, the specific force output from the accelerometer is converted to the navigation coordinate system. After subtracting the gravitational component, inertial acceleration is obtained. Velocity is obtained through a first integration of the inertial acceleration, and displacement is obtained through a second integration. To suppress integral drift, the system introduces two correction methods: first, both displacement and velocity are simultaneously zeroed during each zero-velocity correction; second, when the operator explicitly points to a known reference point, absolute position correction is performed upon operator confirmation via button press. The system uses the spray gun position at the moment the operator presses the start button as the origin, outputting three-dimensional coordinates in real time during operation, with data rate synchronized with attitude.

[0044] The sandblasting media supply and control module is responsible for providing power to the handheld sandblasting gun and executing precise action commands. It includes the main air source pipeline, the abrasive supply unit, and key actuators. An electric pressure regulating valve is connected in series in the compressed air pipeline, and an electric sand regulating valve is connected in series in the abrasive pipeline.

[0045] This module also includes a quick-shutdown valve specifically for emergency shutdown. Pressure sensors and flow meters are installed in the pipeline for real-time feedback of actual pressure and flow. This module uses ramp control to regulate pressure and flow; parameters gradually increase or decrease according to a set rate of change, rather than abruptly. The formula for calculating the step increment for each control cycle is:

[0046]

[0047]

[0048] In the formula, , These represent the step changes in pressure and flow rate, respectively. , For target pressure and target flow, , This is the current actual value. , The slope change rates are for pressure and flow rate, respectively. To control the cycle,

[0049] For example, if the default pressure change rate is 0.05 MPa / s, then the maximum change per step is 0.001 MPa; when the speed is switched from slow (0.6 MPa) to fast (0.15 MPa), the pressure decreases smoothly at a rate of 0.05 MPa / s, which takes 9 seconds to complete.

[0050] The central control module is the brain and decision-making center of the system. It is implemented by a high-performance microcontroller or industrial PLC and has two built-in core knowledge bases: a regional adaptation rule base and a historical operation database.

[0051] The intelligence of the central control module is profoundly reflected in speed negative correlation adjustment, attitude area identification and parameter correction, release safety protection, cumulative sand output and corrosion degree inference, construction of three-dimensional corrosion distribution map, and continuous data-driven self-learning optimization closed loop.

[0052] The speed-negative correlation adjustment strategy determines the reference pressure and flow rate based on the real-time detected movement speed level, following the principle that the faster the speed, the smaller the sandblasting parameters; and the slower the speed, the larger the sandblasting parameters.

[0053] The specific mapping relationships are as follows: Extremely slow speed (0~30mm / s, fine processing) corresponds to a reference pressure of 0.70MPa and a flow rate of 7.5kg / min; slow speed (30~70mm / s, conventional rust removal) corresponds to 0.60MPa and 6.5kg / min; medium speed (70~120mm / s, rapid finishing) corresponds to 0.38MPa and 4.5kg / min; fast speed (>120mm / s, already removed after reaching the standard) corresponds to 0.15MPa and 1.5kg / min. In actual control, the speed changes continuously, and the pressure and flow rate are calculated using linear interpolation to obtain the reference values. The interpolation formula is:

[0054]

[0055] In the formula, , These are the reference pressure and reference flow rate, respectively. These represent the pressure values ​​corresponding to the lower and higher ends of the speed range, respectively. These are the corresponding flow rates. At the current speed, These are the lower and upper boundary values ​​of the speed range, respectively;

[0056] For example, if the current speed is 85 mm / s (between 70 and 120), then: After the baseline value is calculated, the lifting and lowering are performed via ramp control.

[0057] The system employs a posture area recognition and parameter correction strategy. By analyzing the pitch and roll angles of the spray gun, it determines the gate area type corresponding to the current operation in real time and makes targeted corrections to the baseline parameters.

[0058] When the absolute value of the roll angle on the side of the beam is greater than 45° and lasts for more than 0.5 seconds, and the current moving speed is not in the fast setting (speed <120mm / s), it is determined that the operator has inserted the spray gun into the beam to spray the side. At this time, the pressure correction factor is 0.60, the flow correction factor is 0.70, and the handle emits a slow vibration (frequency 2Hz, duty cycle 50%) to remind the operator to pay attention to the thin plate.

[0059] When the pitch angle is less than -20° (gun tip pointing upwards) and lasts for more than 0.5 seconds, it is determined that the operator is spraying the bottom surface of the beam grid from bottom to top. At this time, the pressure correction factor is 1.20, the flow correction factor is 1.10, and the rapid vibration of the handle (frequency 5Hz) indicates the influence of gravity settlement.

[0060] For the sealing surface, when the absolute values ​​of both the pitch angle and roll angle are less than 15° (the spray gun is nearly vertical), and the current speed setting is extremely slow or very slow (<70mm / s), it is determined that the operator is performing fine sandblasting on the water-stop sealing surfaces on both sides of the gate. At this time, the upper limit of pressure is forcibly limited to 0.5MPa and the upper limit of flow rate is 4kg / min. The LED display is constantly lit in blue, and the handle vibrates very lightly and intermittently (0.5Hz).

[0061] In the weld area, if the pitch or roll angle fluctuates within ±10° at a frequency exceeding 2Hz (i.e., the operator is rapidly swinging the spray gun within a small angle range), it is determined that oscillating sandblasting is being performed along the weld. At this time, the original pressure and flow rate (correction factor 1.0) are maintained, but the operator is prompted to maintain a slow oscillation by intermittent vibration of the handle (0.2 seconds of vibration per 1 second).

[0062] Dangerous posture. When the absolute value of the pitch angle is greater than 60° (the nozzle is pointing too high or too low) or the absolute value of the roll angle is greater than 70° (the nozzle is tilted too far to the side), and the duration exceeds 0.3 seconds, it is determined to be a dangerous posture (potentially pointing at the operator or causing sand to bounce and injure people). At this time, the pressure is forcibly reduced to below 0.1MPa (maintaining only a weak airflow), the sand flow is shut off (electric sand regulating valve is fully closed), and at the same time, the red LED flashes (frequency 5Hz), the handle vibrates continuously (100Hz), and a buzzer alarm sounds (3kHz square wave).

[0063] Disengagement Safety Protection Strategy: The central control module continuously monitors the instantaneous speed value output by the movement speed sensing module. When the instantaneous speed exceeds the preset safety threshold (default 800mm / s, adjustable range 500~1500mm / s, set according to the spray gun weight 0.8~1.5kg and twice the normal operating maximum speed of 400mm / s) and the duration exceeds 20ms (to prevent false triggering by spike noise), the system determines that the sandblasting gun has been accidentally released from the operator's hand (e.g., thrown out or slipped). At this time, the central control module immediately executes the highest priority interruption response: within 5ms, it sends a shut-off signal to the quick-cut-off valve, simultaneously sets the target pressure of the electric pressure regulating valve to 0 and executes it immediately (skipping the ramp), and sets the opening of the electric sand regulating valve to 0. The mechanical response time of the quick-cut-off valve is ≤15ms, plus the pipeline depressurization time, ensuring that the compressed air and sand supply are completely cut off within 50ms. After the disengagement protection is triggered, the system enters a locked state, which requires the operator to re-grip the spray gun and press and hold the "reset" button on the handle for 3 seconds to unlock.

[0064] The system accumulates the sand output and records the instantaneous flow rate of the electric sand regulating valve in real time. It also calculates the instantaneous coverage area of ​​the spray gun on the gate surface. The formulas for calculating the length L of the coverage area along the movement direction and the width W perpendicular to the movement direction are as follows:

[0065]

[0066] In the formula, The vertical distance from the spray gun to the gate surface is measured using an added miniature laser rangefinder sensor. The spray angle is half-angle (default 15°, total spray angle 30°). Instantaneous movement speed, The sampling time interval;

[0067] The formula for calculating the instantaneous coverage area is:

[0068] The formula for calculating the sand density per unit time is: The amount of sandblasting at this location is determined by combining the sandblasting dwell time. for By combining the spraying process, the amount of paint sprayed in each area can be determined, which in turn reflects the degree of rust. When the amount of paint sprayed is greater, the degree of rust in that area is greater.

[0069] A three-dimensional rust distribution map is constructed. The system uses the position of the spray gun when the operator presses the start button as the origin and obtains the coordinates (X, Y, Z) of the spray gun in the gate space in real time through a three-dimensional displacement tracking module. In each sampling cycle, the system accumulates the sand output of the grid cell corresponding to the current coordinate (X, Y) and the residence time. After the sandblasting operation is completed, the system generates a two-dimensional grid map covering the entire gate surface. The color intensity of each grid cell represents the total sand output at that location, using a heat map color scale (blue for light rust, green for medium rust, and red for heavy rust). For non-planar areas such as the sides of the beam grid, the system determines the sand output by attitude angle (horizontal) and projects it onto the corresponding virtual plane on the side.

[0070] A continuous data-driven self-learning optimization loop is implemented, treating each sandblasting operation as a complete data sample. The central control module automatically collects and correlates the following data: operation ID, timestamp, gate type, operator ID; speed time series (every 0.2s), attitude angle series, and displacement trajectory (X,Y) series throughout the entire process; pressure / flow commands output at each moment (every 0.2s); cumulative sand output and residence time for each grid; whether the hand-off protection was triggered and its details; and the final rust removal quality inspection results.

[0071] The self-learning algorithm unit uses a decision tree (or random forest) regression model. Input features include velocity, attitude, pressure, flow rate, and sand output for each grid cell, with the output being a quality score. Feature importance analysis is used to uncover potential correlations between control parameters and final quality. After multiple iterations and validations, a stable and efficient strategy is solidified as the optimal operating formula for this gate type and updated to the historical knowledge base.

[0072] The interactive feedback module is responsible for transmitting the decision status of the central control module to the operator in real time. Multi-color indicator lights are installed at the end of the sandblasting gun handle, using different colors and flashing patterns to indicate the current operating mode: solid green for flat / normal mode, slow green flashing for rapid removal, slow yellow flashing for beam side mode, fast yellow flashing for beam bottom mode, solid blue for sealing surface protection mode, white breathing light for weld mode, and flashing red for dangerous posture or drop protection. A vibration motor is embedded in the handle grip, using different vibration frequencies and patterns: slow continuous vibration for beam side, fast continuous vibration for beam bottom, very light intermittent vibration for sealing surface, intermittent vibration for weld, and continuous strong vibration for dangerous posture / drop. A buzzer provides auditory alarm for emergencies such as drop protection and dangerous postures.

[0073] Based on the overall system-level description above, the detailed workflow of this system is executed according to the following steps:

[0074] Step 1: System Initialization and Task Setting. The operator inputs the basic information for this operation on the control box panel, including gate type, gate number, estimated area, target cleanliness level, and base material type. The operator checks if the six-axis inertial measurement unit communication is normal, if the electric pressure regulating valve and electric sand regulating valve are responsive, if the quick-cut-off valve is open, and if the air pressure sensor reading is within the normal range. After the self-test passes, a green breathing light will appear, and the buzzer will sound a short beep.

[0075] Step 2: Preset initial parameters and establish starting point based on regional characteristics. The central control module retrieves the default attitude angle threshold and velocity and pressure mapping curves corresponding to this gate type from the built-in regional adaptation rule base.

[0076] If a successful operation record for the same type of gate exists in the historical operation database, its optimized parameter strategy is directly loaded; otherwise, the standard parameters in the rule base are used as initial values. Simultaneously, the system offsets the baseline pressure range based on the target cleanliness level for this operation. The operator places the spray gun vertically on a known horizontal plane and holds it still for 3 seconds; the system automatically completes attitude zeroing calibration. Then, the operator points the spray gun at the lower left corner of the gate and presses the start button on the spray gun. The system forcibly sets the calculated coordinates of the current 3D displacement tracking module to the origin and records the reading of the laser rangefinder sensor at this time as the reference distance.

[0077] Step 3: Handheld Sandblasting Operation Begins and Real-Time Sensing. The operator pulls the trigger, and the sandblasting gun begins spraying. The movement speed and attitude sensing module samples acceleration and angular velocity at 200Hz, and outputs the calculated speed level, instantaneous speed value, pitch angle, and roll angle at 100Hz. The 3D displacement tracking module outputs the current gun coordinates at 100Hz. The laser rangefinder outputs the distance at 50Hz. All data is transmitted to the central control module in real time via serial port.

[0078] Step 4: Real-time calculation and parameter ramp adjustment of multi-region adaptation algorithm. The central control module performs the following calculations in each control cycle: calculates the reference pressure and reference flow rate through linear interpolation based on the current speed value (after low-pass filtering); determines the region type according to threshold logic based on the current attitude angle, and drives the electric pressure regulating valve and electric sand regulating valve through analog output, so that the actual value gradually approaches the target value.

[0079] Step 5: Accumulated Sand Output and Real-time Update of Rust Distribution Map. In each sampling cycle, the central control module calculates the instantaneous coverage area and sand output density based on the instantaneous flow rate, instantaneous moving speed, and spray gun distance. It also determines the grid index based on the current coordinates, adds the sand output of that time slice to the cumulative sand output of the grid, and simultaneously adds the dwell time. The system updates the rust distribution heat map every 1 second.

[0080] Step Six: Interactive Feedback and Operation Guidance. In each control cycle, the central control module updates the interactive feedback status code based on the currently identified area type and parameter status.

[0081] Step 7: Hand-off safety protection monitoring. The central control module compares the instantaneous velocity with the hand-off threshold in each sampling cycle. If the comparison is true and the duration exceeds 20ms (for 3 consecutive sampling points), the hand-off protection interruption is immediately triggered, cutting off the gas and sand sources within 50ms.

[0082] Step 8: Work Completion and Data Acquisition. After the operator completes the sandblasting work in all areas, release the trigger and click the "End Work" button. The data from the entire work process will be automatically packaged and stored, and the system will generate a final rust distribution heat map and summary report.

[0083] Step Nine: Quality Inspection and Self-Learning Optimization Closed Loop. After the operation is completed, quality inspectors inspect the gate after sandblasting, assess the cleanliness level and roughness of each area, and mark over-blasted and under-blasted areas. These inspection results are input into the system and correlated with the recorded data of the entire process to form a complete data sample. The self-learning algorithm unit analyzes this sample, generates optimization suggestions, and updates the area adaptation rule base.

[0084] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to interchangeably. Each embodiment focuses on describing the differences from other embodiments. In particular, the system embodiments are basically similar to the method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions in the method embodiments.

[0085] The above description is merely an embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of the present invention should be included within the scope of the claims of the present invention.

Claims

1. An automatic sandblasting system for multi-zone adaptation of power station gates, characterized in that, It includes a handheld sandblasting gun execution module, a movement speed and attitude perception module, a three-dimensional displacement tracking module, a sandblasting medium supply and control module, a central control module, and an interactive feedback module; A handheld sandblasting gun execution module includes a handheld sandblasting gun for spraying abrasive onto the surface of a gate; The movement speed and attitude sensing module is used to collect the operator's movement speed and the pitch and roll angles of the spray gun in real time. The three-dimensional displacement tracking module is used to construct the motion trajectory of the spray gun in the three-dimensional space of the gate in real time; The sandblasting medium supply and control module includes an electric pressure regulating valve and an electric sand regulating valve, which are used to regulate the sandblasting pressure and flow rate; The central control module is connected to the movement speed and attitude perception module, the three-dimensional displacement tracking module, and the sandblasting medium supply and control module. The central control module is configured to determine the reference pressure and reference flow rate based on the real-time movement speed detected by the movement speed and attitude perception module, according to the speed negative correlation adjustment strategy of the faster the speed, the smaller the sandblasting parameter, and the slower the speed, the larger the sandblasting parameter. Based on the pitch angle and roll angle, the module determines the gate area type corresponding to the current operation in real time and corrects the parameters of the reference pressure and reference flow rate. The gate area type includes the beam grid side, beam grid bottom, sealing surface, and weld. When the instantaneous speed exceeds the preset safety threshold and the duration exceeds the preset time, it is determined that the sandblasting gun has been accidentally released and an emergency shutdown is triggered. The interactive feedback module, connected to the central control module, is used to provide feedback on the current working status to the operators.

2. The automatic sandblasting system for multi-zone adaptation of power station gates according to claim 1, characterized in that: The movement speed and attitude sensing module reuses data from a six-axis inertial measurement unit, and realizes movement speed detection through acceleration integration and zero-speed correction. The speed detection method is to convert the three-axis acceleration measured by the accelerometer to the workpiece surface coordinate system based on the calculated pitch and roll angles, and extract the acceleration component along the movement direction of the gate plane. The real-time velocity is obtained by integrating the acceleration component over time, and the calculation formula is as follows: In the formula, for Real-time speed at any moment The velocity at the previous moment, The acceleration component is along the direction of movement in the gate plane. For the sampling time interval, when the spray gun is detected to be stationary or the operator releases the trigger, a zero-speed correction is performed, resetting the speed integral state to zero.

3. The automatic sandblasting system for multi-zone adaptation of power station gates according to claim 1, characterized in that: In the aforementioned speed-negative correlation adjustment strategy, the real-time moving speed is divided into extremely slow, slow, medium, and fast speeds. When the speed changes continuously, pressure and flow rate are calculated as baseline values ​​through linear interpolation. The interpolation formula is as follows: , In the formula, , These are the reference pressure and reference flow rate, respectively. These represent the pressure values ​​corresponding to the lower and higher ends of the speed range, respectively. These are the corresponding flow rates. At the current speed, These represent the lower and upper boundary values ​​of the speed range, respectively.

4. The automatic sandblasting system for multi-zone adaptation of power station gates according to claim 1, characterized in that: The central control module is configured to perform attitude region identification and parameter correction according to the following rules: When the absolute value of the roll angle is greater than 45° and lasts for more than 0.5 seconds, and the current moving speed is not in the fast setting, it is judged as the side of the beam grid, with a pressure correction factor of 0.60 and a flow correction factor of 0.

70. When the pitch angle is less than -20° and lasts for more than 0.5 seconds, it is determined to be the bottom surface of the beam grid, with a pressure correction factor of 1.20 and a flow correction factor of 1.

10. When the absolute values ​​of both pitch and roll angles are less than 15°, and the current speed setting is extremely slow or slow, it is determined to be a sealing surface, and the upper limit of pressure is forcibly limited to 0.5MPa and the upper limit of flow rate is 4kg / min. When the pitch or roll angle fluctuates within ±10° at a frequency exceeding 2Hz, it is determined to be a weld area. The original pressure and flow rate are maintained, and the correction factor is 1.

0. When the absolute value of the pitch angle is greater than 60° or the absolute value of the roll angle is greater than 70° and the duration exceeds 0.3 seconds, it is determined to be a dangerous posture, and the pressure is forcibly reduced to below 0.1MPa and the sand flow is shut off.

5. The automatic sandblasting system for multi-zone adaptation of power station gates according to claim 1, characterized in that: In the aforementioned hand-off safety protection, the safety threshold is set to 800 mm / s by default, and the preset time is 20 ms. When the emergency shutdown is triggered, the central control module sends a shutdown signal to the quick-cut-off valve in the sandblasting medium supply and control module within 5 ms. At the same time, the target pressure of the electric pressure regulating valve is set to 0, and the opening of the electric sand regulating valve is set to 0, ensuring that the compressed air and sand supply are completely cut off within 50 ms. After the hand-off protection is triggered, the system enters the locked state.

6. The automatic sandblasting system for multi-zone adaptation of power station gates according to claim 1, characterized in that: The central control module records the instantaneous flow rate of the electric sand regulating valve in real time and calculates the instantaneous coverage area of ​​the spray gun on the gate surface. The calculation formulas for the length L of the coverage area along the movement direction and the width W perpendicular to the movement direction are as follows: In the formula, The vertical distance from the spray gun to the gate surface is measured using an added miniature laser rangefinder sensor. The spray angle is half-angle (default 15°, total spray angle 30°). Instantaneous movement speed The sampling time interval; The formula for calculating the instantaneous coverage area is: The formula for calculating the sand density per unit time is: The amount of sandblasting at this location is determined by combining the sandblasting dwell time. for .

7. The automatic sandblasting system for multi-zone adaptation of power station gates according to claim 1, characterized in that: The central control module also includes a self-learning optimization closed loop. Each sandblasting operation is regarded as a complete data sample, automatically collecting the operation ID, timestamp, gate type, operator ID, speed time series, attitude angle series, displacement trajectory, pressure and flow commands output at each moment, cumulative sand output and residence time of each grid, whether the hand release protection is triggered, and the final rust removal quality inspection result.

8. The automatic sandblasting system for multi-zone adaptation of power station gates according to claim 1, characterized in that: The interactive feedback module includes a multi-color indicator light installed at the tail of the sandblasting gun handle and a vibration motor embedded in the handle. The central control module controls the output of the indicator light and the vibration motor according to the currently identified working mode: flat / normal mode corresponds to solid green; fast removal corresponds to slow green flashing; beam grid side mode corresponds to slow yellow flashing and slow continuous vibration; beam grid bottom mode corresponds to fast yellow flashing and fast continuous vibration; sealing surface protection mode corresponds to solid blue and very light intermittent vibration; weld seam mode corresponds to white breathing light and intermittent vibration; and dangerous posture or drop protection corresponds to red strobe light, continuous strong vibration and buzzer alarm.

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