A robot collaborative control method for wading pier surface spraying

Abstract

The present application relates to the technical field of spraying robots, and in particular to a robot cooperative control method for spraying the surface of a bridge pier in water, comprising: obtaining surface state data and region position data of a processing region, and determining a region to be sprayed; obtaining field position data of a spraying robot, and executing position correspondence to form an effective region; planning spraying and collecting process data, analyzing spraying adjustment data, controlling spraying to obtain updated data; identifying an interruption boundary to form continuation spraying boundary data, planning connected spraying to form spraying results. The present application is advantageous in reducing re-wetting construction, mis-spraying across boundaries, excessive adjustment, missed spraying, and film thickness mutation by combining surface state and waiting time, unifying coordinates and positioning verification, adjusting spraying gun state and film thickness deviation, and controlling continuation spraying of interruption boundaries.

Description

Technical Field

[0001] This invention relates to the field of spraying robots, and more particularly to a robot collaborative control method, electronic device and storage medium for spraying the surface of bridge piers in water. Background Technology

[0002] In the construction of protective coatings for bridge piers spanning rivers, seas, or reservoirs, surface treatment robots are typically used to clean, grind, and inspect the condition of the pier surfaces. Then, spraying robots apply the anti-corrosion or protective coating. The construction area is affected by factors such as water level changes, wave adhesion, surface condensation, wind disturbances, and positioning obstructions. The surface condition of the treated area may change over time, and the location of the area recorded by the two robots may also deviate. In addition, the construction process may be temporarily interrupted due to environmental changes or obstacle avoidance. Therefore, it is necessary to accurately determine the re-spraying position when resuming work.

[0003] Currently, existing technologies typically employ a sequential operation method of first completing surface treatment and then spraying. After the surface treatment robot completes the treatment of the entire area or a segmented area, it sends the area boundary, task number, or completion status to the spraying robot. After receiving the task, the spraying robot completes the spraying of the corresponding area according to the preset trajectory and spraying parameters. If the construction is interrupted, the operation is usually restarted according to the recorded task progress or trajectory position.

[0004] It is evident that existing technologies primarily rely on area boundaries, task numbers, or completion status for task handover, failing to correlate surface treatment quality, surface moisture content, treatment completion time, and actual spatial location. The spraying robot struggles to determine whether the area to be sprayed still meets the spraying conditions and to confirm whether the received area boundary matches the actual location of the bridge pier. Furthermore, existing technologies typically spray continuously according to preset parameters and resume operations based on historical trajectory positions, making it difficult to adapt promptly to changes in spraying distance, spraying angle, and relative movement. After construction is interrupted, spraying may continue in failed areas, or there may be missed spraying, repeated spraying, and uneven film thickness at connection points, affecting the construction quality of the protective coating for water-crossing bridge piers. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies that make it difficult to simultaneously ensure the timeliness and positional consistency of surface treatment area transitions, and to maintain film thickness uniformity during the spraying process and the interrupted spraying process. Therefore, this invention proposes a robot collaborative control method, electronic device, and storage medium for spraying the surface of water-crossing bridge piers.

[0006] To at least solve some of the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0007] Firstly, this invention provides a robot collaborative control method for spraying coating on the surface of water-bearing bridge piers, including:

[0008] The surface condition data and location data of the processing area collected by the surface treatment robot are acquired, and a valid judgment is performed to form the data of the area to be sprayed.

[0009] Acquire the on-site location data of the painting robot, perform location correspondence analysis on the data of the area to be painted, and form valid area confirmation data;

[0010] Based on the valid area confirmation data, the spraying plan is executed, spraying control information is generated to control the spraying robot to spray the area to be sprayed, and spraying process data is collected.

[0011] Perform status analysis on the spraying process data to generate spraying adjustment data;

[0012] Spraying is controlled based on the spraying adjustment data to generate updated process data;

[0013] Interruption boundaries are identified from the update process data to form continuous spray boundary data;

[0014] Based on the spraying adjustment data and the continuous spraying boundary data, the continuous spraying plan is executed, and continuous spraying control information is generated to control the spraying robot to perform continuous spraying from the continuous spraying boundary to form the spraying result.

[0015] Preferably, the surface state data and region location data of the processing area collected by the surface treatment robot are acquired, a valid determination is performed, and the data of the area to be sprayed is formed, including:

[0016] The surface state of the processing area collected by the surface treatment robot is obtained and aggregated according to the processing area to form state data;

[0017] Obtain the boundary of the processing area and perform coordinate unification processing to form regional location data;

[0018] The status data is evaluated for validity and associated with the regional location data to form the area to be sprayed data.

[0019] Preferably, the status data is used to perform a valid determination, and the region location data is associated to form the area to be sprayed data, including:

[0020] Obtain construction configuration data and extract the allowable range of roughness and the allowable range of surface moisture content;

[0021] Surface roughness, surface moisture content, and processing completion time are extracted from the state data.

[0022] Obtain the current time and the effective hold time, and calculate the waiting time between the current time and the processing completion time;

[0023] When the surface roughness is within the allowable range, the surface moisture content is within the allowable range, and the waiting time does not exceed the effective holding time, the area location data is associated to form the area data to be sprayed.

[0024] Preferably, the on-site location data of the spraying robot is acquired, and a location correspondence analysis is performed on the data of the area to be sprayed to form valid area confirmation data, including:

[0025] The system acquires on-site structural features of the bridge piers collected by the spraying robot and performs positioning matching to generate on-site location data.

[0026] A location correspondence analysis is performed on the data of the area to be sprayed and the on-site location data to form valid area confirmation data.

[0027] Preferably, a location correspondence analysis is performed on the data of the area to be sprayed and the on-site location data to form valid area confirmation data, including:

[0028] Extract the region location data from the area to be sprayed data, and extract the position, posture and positioning matching deviation of the spraying robot from the on-site location data;

[0029] Based on the position and posture of the painting robot, coordinate conversion is performed on the area position data to form on-site area position data;

[0030] Obtain the allowable positioning matching deviation. When the positioning matching deviation does not exceed the allowable positioning matching deviation, collect the on-site area location data to form valid area confirmation data.

[0031] Preferably, state analysis is performed on the spraying process data to generate spraying adjustment data, including:

[0032] Perform a spraying state difference analysis on the spraying process data to generate spraying state deviation data;

[0033] Parameter correspondence analysis is performed on the spraying state deviation data to generate spraying adjustment data.

[0034] Preferably, parameter correspondence analysis is performed on the spraying state deviation data to form spraying adjustment data, including:

[0035] Extract distance deviation, angle deviation, and speed deviation from the spraying state deviation data;

[0036] Perform deviation conversion on the distance deviation, angle deviation, and speed deviation to determine the corresponding adjustment amount;

[0037] Extract the insufficient film thickness and excessive film thickness from the spraying state deviation data;

[0038] Based on the pre-stored spraying calibration table, perform parameter matching for insufficient film thickness and excessive film thickness to determine the parameter adjustment amount;

[0039] The control state is determined based on the spraying state deviation data; when at least one deviation exists, the adjustment starting point is determined based on the position of the first deviation trajectory, and the current spraying parameters are corrected according to the adjustment amount of each parameter; when none of the deviations exist, the current spraying parameters are used to form spraying adjustment data.

[0040] Preferably, identifying interruption boundaries from the update process data to form re-spray boundary data includes:

[0041] The interruption status is identified during the update process to determine the interruption time.

[0042] Based on the interruption time and update process data, continuous qualified film-forming boundaries are identified, and interruption boundaries are formed;

[0043] Based on the interruption boundary, the unfinished spraying area is determined and the boundary film thickness is collected to form the continuous spraying boundary data.

[0044] Preferably, based on the spraying adjustment data and the continuous spraying boundary data, continuous spraying planning is performed to generate continuous spraying control information, so as to control the spraying robot to perform continuous spraying from the continuous spraying boundary to form a spraying result, including:

[0045] Perform a connection range analysis on the continuous spray boundary data to form continuous spray trajectory data;

[0046] Continuous spraying parameter configuration is performed on the spraying adjustment data and continuous spraying trajectory data to generate continuous spraying control information;

[0047] Based on the continuous spray control information, the continuous spraying is controlled and the result is verified to form the spraying result.

[0048] Preferably, the continuous spray boundary data is subjected to a connection range analysis to form continuous spray trajectory data, including:

[0049] Extract the interruption boundary, incomplete spraying area, and boundary film thickness data from the continuous spraying boundary data;

[0050] Perform film thickness extremum extraction on the boundary film thickness data to obtain the minimum film thickness and the maximum film thickness;

[0051] Obtain the target film thickness range, compare the minimum and maximum film thicknesses with the target film thickness range, and determine the overlap width;

[0052] The starting point and connection trajectory for continued spraying are determined based on the interruption boundary and the unfinished spraying area;

[0053] The continuous spraying start point, connection trajectory, and overlap width are collected to form continuous spraying trajectory data.

[0054] In a second aspect, the present invention provides an electronic device including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of the method in the first aspect.

[0055] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of the method in the first aspect.

[0056] Compared with the prior art, the present invention has the following beneficial effects:

[0057] I. By incorporating surface roughness, surface moisture content, and waiting time into the regional handover process, this invention helps to prevent the spraying robot from continuing to work on the already damp bridge pier surface, thereby improving the quality of subsequent construction.

[0058] Second, this invention determines the position and posture of the spraying robot by utilizing the on-site structural features of the bridge pier, converts the treated area to the current working coordinates of the spraying robot, and verifies the positioning matching results. This helps to ensure that the spraying trajectory falls into the area where the surface treatment has been completed, reducing the spraying of areas beyond the boundary and the accidental spraying of untreated surfaces.

[0059] Third, by determining the adjustment amounts of the spray gun distance, incident angle, and relative moving speed, and combining the film thickness deficiency and excess to determine the spraying parameter adjustment amounts, this invention helps to distinguish between abnormal spray gun spatial state, abnormal movement state, and abnormal coating thickness, and reduces over-adjustment caused by inaccurate judgment of the cause of the abnormality.

[0060] Fourth, this invention determines the re-spraying position by the actual interruption boundary and adjusts the overlap width according to the boundary film thickness, which helps to reduce missed spraying, repeated spraying and sudden changes in film thickness at the interruption position, so that the coating before and after the interruption is continuously connected. Attached Figure Description

[0061] Figure 1 This is a flowchart of the method of the present invention.

[0062] Figure 2 This is a comparison diagram of the effects of the present invention and the prior art. Detailed Implementation

[0063] To make the technical means, creative features, objectives, and effects of this invention easier to understand, the invention is further described below with reference to specific embodiments. However, the following embodiments are merely preferred embodiments of this invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments described herein without creative effort are all within the protection scope of this invention.

[0064] A specific embodiment of the present invention discloses a robot collaborative control method for spraying coating on the surface of water-crossing bridge piers. Please refer to [link to relevant documentation]. Figure 1 ,include:

[0065] S1. Acquire surface state data and area location data of the processing area collected by the surface treatment robot, perform valid judgment, and form data of the area to be sprayed;

[0066] S2. Obtain the on-site location data of the painting robot, perform position correspondence analysis on the data of the area to be painted, and form valid area confirmation data;

[0067] S3. Based on the valid area confirmation data, execute the spraying plan, generate spraying control information to control the spraying robot to spray the area to be sprayed, and collect spraying process data.

[0068] S4. Perform state analysis on the spraying process data to generate spraying adjustment data;

[0069] S5. Control the spraying according to the spraying adjustment data to generate updated process data;

[0070] S6. Identify the interruption boundary from the update process data to form the spraying continuation boundary data;

[0071] S7. Based on the spraying adjustment data and the continuous spraying boundary data, perform continuous spraying planning and generate continuous spraying control information to control the spraying robot to perform continuous spraying from the continuous spraying boundary to form the spraying result.

[0072] It should be noted that this embodiment is applied to the splash zone and wet / dry alternating zone of the circular piers of cross-river bridges. The surface treatment robot can adopt a wall-attached moving structure to complete grinding and condition detection along the pier surface; the spraying robot can adopt a hexacopter UAV equipped with a high-pressure airless spraying device, a vision positioning device, and a film thickness detection component; the ground control console receives data from the two robots via wireless communication and sends control information to the two robots.

[0073] Before construction, the ground control console acquires pier design data and on-site measurement data to create a pier area map. The pier area map uses standardized pier coordinates to record the curved contours of the pier surface, the results of the processed area division, the coordinates of the area boundaries, reference features used for visual positioning, and the positions of each reference feature. Both the surface treatment robot and the spraying robot record or convert their work positions using the aforementioned standardized pier coordinates.

[0074] Construction personnel input the target film thickness range, allowable roughness range, allowable surface moisture content range, spray gun distance range, incident angle range, relative movement speed range, spray flow rate range, effective spray width, initial overlap width, allowable overlap width range, allowable deviation of spraying position, and data collection cycle at the ground control console to form construction configuration data. The target film thickness range, allowable roughness range, and allowable surface moisture content range are determined according to the bridge pier protection design requirements and coating process documents; the spray gun distance, incident angle, relative movement speed, spray flow rate, effective spray width, initial overlap width, and allowable overlap width range are determined through on-site test spraying of the same batch of coatings on test panels of similar materials; the allowable deviation of spraying position is determined based on the minimum safe distance between the edge of the planned spraying range and the boundary of the treated area. The effective holding time and allowable positioning matching deviation are determined according to the calibration process described later and then written into the construction configuration data. The actual film thickness used for comparison uses the same film thickness state and unit of measurement as the target film thickness range.

[0075] As an optional implementation, after the bridge pier surface is polished, wave adhesion and surface condensation may cause the area to become damp again. Simply recording the completed state does not prove that the area is still effective during spraying. Step S1 can solve the above problems and specifically includes the following:

[0076] S1.1 Obtain the surface state of the processing area collected by the surface treatment robot, and collect it according to the processing area to form state data;

[0077] After the surface treatment robot completes its work in a treatment area, it obtains the surface roughness and surface moisture content of that area through its built-in roughness detection component and moisture content detection component, and records the time of completion of the treatment. The ground control console collects the above information according to the treatment area to form status data. Each status data corresponds to only one treatment area to avoid mixing the detection results of different areas.

[0078] S1.2 Obtain the boundary of the processing area and perform coordinate unification processing to form regional location data;

[0079] The surface treatment robot obtains the area identifier and boundary of the current processing area from the established bridge pier area map, converts the position points on the area boundary to unified bridge pier coordinates, and arranges the converted position points according to the boundary order; the ground control console collects the area identifier and the converted area boundary coordinates to form area position data, thereby reducing the impact of the robot's own coordinate changes on area handover.

[0080] S1.3. Perform a valid determination on the status data and associate it with the regional location data to form the area to be sprayed data;

[0081] S1.3.1 Obtain construction configuration data and extract the allowable range of roughness and the allowable range of surface moisture content;

[0082] The ground control console reads the construction configuration data generated before construction and extracts the allowable range of roughness and the allowable range of surface moisture content.

[0083] Among them, the allowable roughness range is used to determine whether the surface of the bridge pier after grinding meets the coating adhesion requirements, and the allowable surface moisture content range is used to determine whether the surface of the bridge pier has become damp again due to waves and condensation.

[0084] S1.3.2 Extract surface roughness, surface moisture content, and processing completion time from the state data;

[0085] The ground control console reads status data according to the processing area and extracts the surface roughness, surface moisture content and processing completion time corresponding to the current area.

[0086] S1.3.3 Obtain the current time and the effective holding time, and calculate the waiting time between the current time and the processing completion time;

[0087] The effective retention time represents the longest time that the bridge pier surface can still be directly sprayed after treatment. It is obtained by the following method: before construction, test plates of the same material are treated with the same surface. The test plates are then placed under the current water level and splash conditions, and the surface moisture content is checked at regular intervals. Then, the time when the surface moisture content first exceeds the allowable range is subtracted from the time when the treatment is completed to obtain the single retention time. After multiple tests, the shorter single retention time is taken and a safety margin is deducted to obtain the effective retention time.

[0088] The ground control console obtains the current time and subtracts the processing completion time from it to get the waiting time. The waiting time reflects the time the processed area has been exposed to the field environment, and can directly determine whether the surface treatment result has become invalid due to excessive waiting.

[0089] S1.3.4 When the surface roughness is within the allowable range, the surface moisture content is within the allowable range, and the waiting time does not exceed the effective holding time, the area location data is associated to form the area data to be sprayed.

[0090] The ground control console compares the surface roughness with the allowable roughness range, the surface moisture content with the allowable surface moisture content range, and the waiting time with the effective holding time. When all three conditions are met, the status data is associated with the regional location data of the same processing area to form the area to be sprayed data. The area to be sprayed data represents the bridge pier area that still meets the spraying requirements and has a clearly defined boundary.

[0091] If any condition is not met, an instruction message is generated to re-process the surface.

[0092] This method incorporates surface quality, moisture level, and waiting time into the area handover process, which can prevent the spraying robot from continuing to work on the already damp bridge pier surface, thus affecting the quality of subsequent construction.

[0093] As an optional implementation, when the surface treatment robot and the spraying robot perform positioning separately, water reflection, bridge pier curvature obstruction, and robot motion disturbances may cause differences in the position results obtained by the two robots. Even if the area numbers are the same, if the spraying robot directly plans its spraying trajectory based on its own positioning results, the spraying range may still deviate from the area already processed by the surface treatment robot. In this embodiment, step S2 can solve the above problems, specifically including the following:

[0094] S2.1. Obtain the on-site structural features of the bridge pier collected by the spraying robot and perform positioning matching to form on-site location data;

[0095] After the painting robot arrives near the area to be painted, it collects on-site images of the bridge pier through its built-in visual positioning device and extracts the structural features of the bridge pier surface from the on-site images. The bridge pier area map has pre-recorded reference features corresponding to the on-site structural features, as well as the positions of each reference feature in the unified bridge pier coordinate system.

[0096] The painting robot matches the on-site structural features with reference features in the bridge pier area map to form multiple sets of corresponding on-site structural features and reference features. The ground control console performs coordinate registration based on the positional correspondence of each set of matched features and calculates the position and attitude of the painting robot in the unified bridge pier coordinate system.

[0097] The ground control console then transforms each on-site structural feature into a unified pier coordinate system based on the calculated position and orientation. For each set of matching features, the difference between the transformed on-site structural feature and the corresponding reference feature is calculated in each coordinate direction. The square root of the sum of the squares of these differences is then calculated to obtain the spatial distance for that set of matching features. The ground control console selects the maximum value from all spatial distances to form the positioning matching deviation. This deviation represents the maximum spatial difference between the on-site structural feature and the map reference feature after the painting robot completes on-site positioning, reflecting the degree of consistency between the positioning result and the map of the pier area.

[0098] The ground control console collects the position, posture, and positioning deviation of the painting robot to form on-site position data.

[0099] By using the physical structural features of the bridge piers to determine the position and posture of the painting robot, the cumulative offset caused by relying solely on the robot's motion records for positioning can be reduced. Furthermore, by using the maximum spatial distance to form the positioning matching deviation, local feature matching anomalies can be directly detected, avoiding the average result from masking large matching errors.

[0100] S2.2 Perform position correspondence analysis on the data of the area to be sprayed and the on-site location data to form valid area confirmation data;

[0101] S2.2.1 Extract the area location data from the area to be sprayed data, and extract the position, posture and positioning matching deviation of the spraying robot from the on-site location data;

[0102] The ground control console extracts the area location data from the area to be sprayed data. The area location data is generated by the surface treatment robot, which records the area number and area boundary coordinates of the current area to be sprayed. The area boundary coordinates are represented using a unified bridge pier coordinate system.

[0103] The ground control console then extracts the position, attitude, and positioning matching deviation of the painting robot from the on-site location data. The position of the painting robot represents its current position in the unified bridge pier coordinates, the attitude represents its current orientation in the unified bridge pier coordinates, and the positioning matching deviation represents the maximum spatial difference between the on-site structural features and the map reference features after positioning matching.

[0104] Regional location data indicates the location of the area already processed by the surface treatment robot on the bridge pier, while on-site location data indicates the current location and orientation of the spraying robot. Extracting these two types of data separately avoids directly using the area boundary recorded by the surface treatment robot as the area boundary in the current working coordinates of the spraying robot.

[0105] S2.2.2. Based on the position and posture of the painting robot, perform coordinate conversion on the area position data to form on-site area position data;

[0106] The ground control console sequentially reads the regional boundary coordinates, which are represented by the same pier coordinates, from the regional location data, and reads the position and posture of the painting robot, which are represented by the same pier coordinates, from the on-site location data.

[0107] For each region boundary coordinate, the ground control console subtracts the value of the painting robot's position in the corresponding coordinate direction from the value of the boundary coordinate in each coordinate direction to obtain the relative position of the boundary point with respect to the painting robot.

[0108] Then, according to the reverse rotation relationship corresponding to the posture of the painting robot, the coordinate rotation of the relative position is performed to obtain the position of the boundary point in the current working coordinates of the painting robot.

[0109] The ground control console arranges the converted boundary coordinates of each area according to the original boundary order, and collects the area number and the converted area boundary coordinates to form on-site area location data. The on-site area location data represents the position of the area to be sprayed recorded by the surface treatment robot in the current working coordinates of the spraying robot.

[0110] By using the position and orientation of the painting robot to perform coordinate conversion of the area boundary, the area to be sprayed recorded by the surface treatment robot can correspond to the current working space of the painting robot, reducing trajectory deviation caused by changes in the position and orientation of the painting robot.

[0111] S2.2.3. Obtain the allowable positioning matching deviation. When the positioning matching deviation does not exceed the allowable positioning matching deviation, collect the on-site area location data to form valid area confirmation data.

[0112] The allowable positioning matching deviation represents the maximum matching residual that the positioning matching result can be used for coordinate conversion of the area to be sprayed and spraying control.

[0113] Before construction, the spraying robot is repeatedly positioned at multiple known bridge pier reference locations. During each positioning, the positioning matching deviation is calculated according to the method in step S2.1, and the position calculated by the spraying robot is compared with the position measured manually to obtain the actual positioning error.

[0114] The ground control console arranges the positioning matching deviations in ascending order and uses each deviation as a candidate deviation threshold. For each candidate deviation threshold, positioning records whose deviations do not exceed that threshold are selected. When the actual positioning errors corresponding to all selected records do not exceed the allowable deviation of the spraying position, the candidate deviation threshold is determined as a valid candidate value. The ground control console selects the maximum value from the valid candidate values ​​as the allowable positioning matching deviation.

[0115] The allowable deviation of the spraying position refers to the maximum allowable offset of the actual spraying position of the spraying robot from the planned spraying position. Before construction, the allowable deviation of the spraying position is determined based on the minimum safety distance reserved between the edge of the planned spraying area and the boundary of the treated area, and the allowable deviation of the spraying position shall not exceed the minimum safety distance.

[0116] By using both positioning matching deviation and actual positioning error to calibrate the allowable positioning matching deviation, the threshold can be made to correspond to the actual positioning accuracy of the painting robot, avoiding direct comparison of two errors with different meanings.

[0117] The ground control console compares the positioning matching deviation with the allowable positioning matching deviation. If the positioning matching deviation does not exceed the allowable positioning matching deviation, it indicates that the on-site positioning result of the painting robot meets the coordinate conversion requirements of the area to be painted. The ground control console then aggregates the area number, on-site area location data, painting robot position and attitude to form valid area confirmation data.

[0118] If the positioning and matching deviation exceeds the allowable deviation, the ground control console will not generate valid area confirmation data and will send repositioning information to the painting robot. The painting robot will then re-acquire images of the bridge pier and perform positioning and matching to generate updated on-site location data. The ground control console will then re-perform coordinate conversion and deviation comparison based on the updated on-site location data. If the updated positioning and matching deviation does not exceed the allowable deviation, valid area confirmation data will be generated; otherwise, the painting will remain stopped, awaiting manual verification.

[0119] The valid area confirmation data indicates that the area to be sprayed formed by the surface treatment robot has been transferred to the current working coordinates of the spraying robot, and the on-site positioning results of the spraying robot meet the spraying requirements.

[0120] This implementation method first uses the on-site structural features to determine the position and posture of the spraying robot, then converts the processed area to the current working coordinates of the spraying robot, and verifies the positioning matching results. This enables the spraying trajectory to fall into the area where the surface treatment has been completed, reducing the spraying of areas beyond the boundary and the accidental spraying of untreated surfaces.

[0121] As an optional implementation, if the bridge pier surface is a continuous curved surface, the spray gun distance, incident angle, and relative movement speed of the spraying robot will change with position. If it is difficult to adapt to the bridge pier surface, it will affect the spraying quality. Step S3 can solve the above problem, specifically:

[0122] S3. Based on the valid area confirmation data, execute the spraying plan, generate spraying control information to control the spraying robot to spray the area to be sprayed, and collect spraying process data.

[0123] The spraying plan involves dividing the bridge pier area corresponding to the valid area confirmation data into multiple spraying strips that can be continuously covered, and configuring spraying parameters for each spraying strip.

[0124] The ground control console reads the area identifier, on-site area location data, and the position and posture of the painting robot from the valid area confirmation data, and reads the curved contour corresponding to the area identifier from the bridge pier area map. The curved contour is represented using a unified bridge pier coordinate system. Based on the position and posture of the painting robot, the ground control console converts the curved contour to the current working coordinates of the painting robot using the same coordinate conversion method as in step S2.2.2, thus forming the on-site curved contour.

[0125] The ground control console reads the area boundary corresponding to the location data of the site area within the curved surface contour, and reads the effective spray width and the initial overlap width. The spray band spacing is obtained by subtracting the initial overlap width from the effective spray width.

[0126] The effective spray width represents the width of a qualified continuous coating that can be formed in a single spraying. The initial overlap width represents the width that adjacent spray bands cover together. The spray band spacing represents the lateral distance between the center lines of two adjacent spray tracks along the surface of the bridge pier. The ground control console arranges the spray tracks sequentially according to this spacing, so that adjacent spray bands cover each other according to the initial overlap width, thereby reducing missed spraying and excessive overlap between spray bands.

[0127] Starting from one side of the area boundary, the ground control console sequentially determines the centerline of each spraying strip on the curved surface contour according to the spacing of the spraying strips. The intersection of each centerline with the area boundary forms the planned start and end positions of the corresponding spraying strip.

[0128] The ground control console assigns spraying belt labels to each spraying belt according to their arrangement, determines the spraying belt execution direction based on the extension direction of each center line, and determines the lateral direction of the spraying belt based on the direction perpendicular to the spraying belt execution direction on the curved surface contour.

[0129] The ground control console connects the spraying belts in opposite directions to adjacent belts, ensuring that the planned end position of the previous spraying belt is sequentially connected to the planned start position of the next spraying belt, forming a continuous reciprocating spraying trajectory. The spraying trajectory records the identification of each spraying belt, its planned start position, planned end position, spraying belt execution direction, and lateral direction.

[0130] For example, if the effective spray width is 30 cm and the initial overlap width is 5 cm, then the spray spacing is 25 cm, which means that the lateral distance between the center lines of adjacent spray trajectories along the surface of the bridge pier is 25 cm.

[0131] Subsequently, the ground control console reads the initial values ​​of spray gun distance, incident angle, relative moving speed, and spray flow rate from the construction configuration data, collects the area number, spray trajectory, and initial values ​​into spray control information, and sends it to the spraying robot. The spraying robot moves according to the spray trajectory and controls the high-pressure airless spraying device to perform spraying according to the corresponding parameters.

[0132] During the spraying process, the spraying robot records the current spraying zone markings, current trajectory position, spray gun distance, incident angle, relative movement speed, spraying flow rate, spray gun opening and closing status, and actual film thickness according to a fixed collection cycle. It also collects the records corresponding to the same collection time according to the collection time to form spraying process data, and then sends the spraying process data to the ground control console.

[0133] The data collection cycle is determined before construction based on the sampling capacity of the film thickness detection component and the maximum relative movement speed allowed by the spraying robot, and is written into the construction configuration data.

[0134] As an optional implementation, wind disturbances and changes in robot posture can cause the actual film thickness to deviate from the target film thickness. Simply determining whether the robot has completed its trajectory does not indicate whether the coating is uniform. This implementation method can solve the above problems, specifically:

[0135] S4. Perform state analysis on the spraying process data to generate spraying adjustment data;

[0136] S4.1 Perform a spraying state difference analysis on the spraying process data to generate spraying state deviation data;

[0137] The ground control console receives the spraying process data sent by the spraying robot and compares the spray gun distance, incident angle, and relative movement speed in the spraying process data with the corresponding ranges in the construction configuration data.

[0138] When the spray gun distance is higher than the upper limit of the spray gun distance range, the difference between the current spray gun distance and the upper limit is used as the distance deviation; when the spray gun distance is lower than the lower limit of the spray gun distance range, the difference between the lower limit and the current spray gun distance is used as the distance deviation; when the spray gun distance is within the spray gun distance range, the distance deviation is recorded as zero.

[0139] When the incident angle is higher than the upper limit of the incident angle range, the difference between the current incident angle and the upper limit is used as the angle deviation; when the incident angle is lower than the lower limit of the incident angle range, the difference between the lower limit and the current incident angle is used as the angle deviation; when the incident angle is within the incident angle range, the angle deviation is recorded as zero.

[0140] When the relative speed is higher than the upper limit of the relative speed range, the difference between the current relative speed and the upper limit is used as the speed deviation; when the relative speed is lower than the lower limit of the relative speed range, the difference between the lower limit and the current relative speed is used as the speed deviation; when the relative speed is within the relative speed range, the speed deviation is recorded as zero.

[0141] When the actual film thickness is lower than the lower limit of the target film thickness range, the difference between the lower limit of the target film thickness range and the actual film thickness is taken as the insufficient film thickness; otherwise, the insufficient film thickness is recorded as zero. When the actual film thickness is higher than the upper limit of the target film thickness range, the difference between the actual film thickness and the upper limit of the target film thickness range is taken as the excessive film thickness; otherwise, the excessive film thickness is recorded as zero.

[0142] The ground control console collects distance deviation, angle deviation, speed deviation, insufficient film thickness, and excessive film thickness according to the trajectory position, forming spraying status deviation data.

[0143] S4.2 Perform parameter correspondence analysis on the spraying state deviation data to form spraying adjustment data;

[0144] S4.2.1 Extract distance deviation, angle deviation, and speed deviation from the spraying state deviation data;

[0145] The ground control console reads the spraying status deviation data according to the trajectory position and extracts the distance deviation, angle deviation and speed deviation corresponding to the same position.

[0146] By extracting the three types of deviations, it is possible to distinguish between abnormal distance between the robot and the bridge pier, abnormal spray gun orientation, and abnormal movement status.

[0147] S4.2.2 Perform deviation conversion on the distance deviation, angle deviation and speed deviation to determine the corresponding adjustment amount;

[0148] When the spray gun distance is greater than the upper limit of the spray gun distance range, the difference between the current spray gun distance and the upper limit is used as the distance adjustment amount, and the distance adjustment direction is determined to move closer to the bridge pier; when the spray gun distance is less than the lower limit of the spray gun distance range, the difference between the lower limit and the current spray gun distance is used as the distance adjustment amount, and the distance adjustment direction is determined to move away from the bridge pier.

[0149] When the incident angle is greater than the upper limit of the incident angle range, the difference between the current incident angle and the upper limit is used as the angle adjustment amount; when the incident angle is less than the lower limit of the incident angle range, the difference between the lower limit and the current incident angle is used as the angle adjustment amount; the ground control console determines the direction of the spray gun adjustment based on the direction of the angle deviation, so that the adjusted incident angle can return to the incident angle range.

[0150] When the relative movement speed is greater than the upper limit of the relative movement speed range, the difference between the current relative movement speed and the upper limit is used as the speed adjustment amount, and the speed adjustment direction is determined to decrease the relative movement speed; when the relative movement speed is less than the lower limit of the relative movement speed range, the difference between the lower limit and the current relative movement speed is used as the speed adjustment amount, and the speed adjustment direction is determined to increase the relative movement speed.

[0151] S4.2.3 Extract the insufficient film thickness and excessive film thickness from the spraying state deviation data;

[0152] S4.2.4. Based on the pre-stored spraying calibration table, perform parameter matching for insufficient film thickness and excessive film thickness to determine the parameter adjustment amount;

[0153] The spray calibration table is generated through single-parameter test sprays before construction. The construction personnel first divide the film thickness into multiple non-overlapping deviation ranges according to the degree of insufficient film thickness and the degree of excessive film thickness. For each deviation range, the spray gun distance, incident angle and another spraying parameter are kept unchanged, and the relative moving speed and spraying flow rate are changed respectively. The parameter change, the actual film thickness after adjustment and the coating surface condition are recorded each time.

[0154] The ground control console retains test spray records where the adjusted film thickness falls within the target film thickness range, no sagging or exposed substrate appears on the coating surface, and the adjusted parameters remain within the corresponding allowable range, forming candidate adjustment records. For each candidate adjustment record, the parameter change is divided by the parameter value before adjustment to obtain the relative adjustment ratio. The ground control console selects the candidate adjustment record with the smaller relative adjustment ratio and writes the corresponding parameter name, adjustment direction, and adjustment amount into the spray calibration table as the recommended adjustment item for that film thickness deviation range. If only one test spray record meets the requirements, that item is directly determined as the recommended adjustment item.

[0155] When the actual film thickness is lower than the lower limit of the target film thickness range, the ground control console should consult the spraying calibration table based on the range where the film thickness is insufficient; when the actual film thickness is higher than the upper limit of the target film thickness range, the spraying calibration table should be consulted based on the range where the film thickness exceeds the limit.

[0156] The ground control console reads the recommended adjustment items and adjustment amounts for the corresponding range, and combines them with the current spraying parameters to obtain the adjusted relative moving speed or spraying flow rate.

[0157] When both speed deviation and film thickness deviation exist in the spraying condition deviation data, and the spraying calibration table recommends adjusting the relative movement speed, the ground control console first corrects the relative movement speed to the range of relative movement speed based on the speed deviation and speed adjustment direction, and then executes the adjustment amount recorded in the spraying calibration table based on the corrected relative movement speed.

[0158] If the adjusted relative speed remains within the range of relative speeds, it is taken as the final relative speed; if the adjusted relative speed exceeds the range, the corresponding endpoint of the range is taken as the final relative speed. The spray calibration table recommends adjusting the spray flow rate directly based on the current spray flow rate, ensuring that the adjusted spray flow rate remains within the spray flow rate range.

[0159] For example, if the target film thickness range is 280 micrometers to 320 micrometers, the current relative moving speed is 0.30 meters per second, the current spraying flow rate is 120 milliliters per minute, and the actual film thickness is detected to be 250 micrometers, then the film thickness deficiency is 30 micrometers, which falls within the film thickness deficiency range of 21 to 40 micrometers.

[0160] The following two qualified records were obtained from the trial spraying before construction:

[0161] By reducing the relative moving speed from 0.30 m / s to 0.25 m / s, the actual film thickness after adjustment is 296 micrometers, and there are no drips or exposed substrates on the coating surface. The relative adjustment ratio is approximately 16.7%.

[0162] The spray flow rate was increased from 120 ml / min to 132 ml / min, and the actual film thickness after adjustment was 304 micrometers. The coating surface was free of sagging and exposed substrate. The relative adjustment ratio was 10%.

[0163] Since the relative adjustment ratio corresponding to increasing the spray flow rate is small, the ground control console records an increase of 12 ml / min in the spray flow rate as a recommended adjustment within the 21-micron to 40-micron insufficient film thickness range of the spray calibration table. When a film thickness deficiency of 30 microns occurs on site, the ground control console directly adjusts the spray flow rate from 120 ml / min to 132 ml / min.

[0164] If the coating shows sagging after increasing the spray flow rate, or if the adjusted spray flow rate exceeds the spray flow rate range, then the test spray record will not be used as a candidate adjustment record, and the test spray record with reduced relative moving speed will be selected instead.

[0165] By determining the adjustment amounts for the spray gun distance, incident angle, and relative moving speed, and then combining these with the amount of insufficient or excessive film thickness to determine the adjustment amounts for the spraying parameters, it is possible to distinguish between abnormal spray gun spatial state, abnormal movement state, and abnormal coating thickness. This avoids directly adjusting the spraying flow rate based solely on film thickness deviation and reduces over-adjustment caused by inaccurate judgment of the cause of the abnormality.

[0166] S4.2.5 Determine the control state based on the spraying state deviation data; if at least one deviation exists, determine the adjustment starting point based on the position of the first deviation trajectory, and correct the current spraying parameters according to the adjustment amount of each parameter; if none of the deviations exist, use the current spraying parameters to form spraying adjustment data;

[0167] The ground control console extracts the spraying strip identifier and actual trajectory position corresponding to the latest acquisition time from the spraying process data, and determines the actual trajectory position as the current execution position.

[0168] The ground control console reads the spraying status deviation data according to the execution sequence of the spraying trajectory. When at least one of the following deviations is greater than zero: distance deviation, angle deviation, speed deviation, insufficient film thickness, and excessive film thickness, the control state is set to parameter correction state; when all of the above deviations are zero, the control state is set to parameter hold state.

[0169] In parameter correction mode, the ground control console determines the first deviation trajectory position as the trajectory position where a non-zero deviation first appears along the spraying trajectory, and reads the planned trajectory corresponding to the current spraying zone from the spraying control information.

[0170] Starting from the first deviation trajectory position, the ground control console sequentially compares each planned trajectory position with the actual trajectory position record in the spraying process data along the execution direction of the current spraying zone. The nearest planned trajectory position that is after the current execution position and for which there is no actual trajectory position record is determined as the adjustment starting point.

[0171] The ground control console reads the spray gun distance, incident angle, relative movement speed, and spray flow rate corresponding to the first deviation trajectory position as the current spraying parameters, and corrects the corresponding parameters according to the adjustment amount, adjustment direction, and processing sequence determined in steps S4.2.2 and S4.2.4 to obtain the adjustment parameters.

[0172] The ground control console collects parameter correction status, adjustment starting point, and adjustment parameters to form spraying adjustment data.

[0173] When parameters are held, the ground control console does not generate adjustment start point or parameter adjustment amount. Instead, it aggregates the parameter holding status, current spraying band identifier, current execution position, and current spraying parameters to form spraying adjustment data.

[0174] S5. Control the spraying according to the spraying adjustment data to generate updated process data;

[0175] The ground control console reads the control status from the spraying adjustment data. When the control status is in parameter correction mode, it sends the adjustment start point and adjustment parameters to the spraying robot, controlling the spraying robot to continue spraying from the adjustment start point using the adjustment parameters; when the control status is in parameter hold mode, it controls the spraying robot to continue working using the current spraying parameters from the planned trajectory position after the current execution position.

[0176] The spraying robot continues to record the current spraying band markers, trajectory positions, spray gun opening / closing status, and actual film thickness according to a fixed data collection cycle. These records are then aggregated according to the collection time to form update process data. This update process data records the spraying trajectory, spray gun opening / closing status, and actual film formation state after the spraying adjustment data is executed, and is distinguishable from the spraying process data before the spraying adjustment data is generated. The update process data records the actual spraying state after the spraying adjustment data is executed, and is distinguishable from the spraying process data before the spraying adjustment data is generated.

[0177] As an alternative implementation method, when the spraying robot stops working due to wind, waves, water level changes, or obstacle avoidance, the robot's stopping position may differ from the actual film boundary on the bridge pier surface. In view of this, the present invention proposes the following working method.

[0178] S6. Identify the interruption boundary from the update process data to form the spraying continuation boundary data;

[0179] S6.1 Perform interruption status identification on the update process data to determine the interruption time;

[0180] The ground control console extracts the spray gun opening and closing status corresponding to each acquisition time from the update process data in sequence, and arranges them in the order of acquisition time to form a spray gun status sequence.

[0181] The ground control console sequentially compares the on / off states of the spray guns at two adjacent acquisition times in the spray gun state sequence. If the previous acquisition time shows the spray gun is on and the next acquisition time shows the spray gun is off, the next acquisition time is determined as the spray gun off time.

[0182] The ground control console reads the spray band identifier and trajectory position corresponding to the moment the spray gun closes, and then reads the planned termination position of the corresponding spray band from the spray control information based on the spray band identifier. The ground control console calculates the distance between the trajectory position corresponding to the moment the spray gun closes and the planned termination position of the current spray band. When the distance does not exceed the allowable deviation of the spray position, and the subsequent trajectory position corresponds to the next spray band, the spray gun closure is determined as a spray band switch, not as a spray interruption.

[0183] When the distance between the trajectory position corresponding to the moment the spray gun is closed and the planned end position of the current spraying belt exceeds the allowable deviation of the spraying position, and there is no subsequent trajectory position record of the current spraying belt in the subsequent update process data, the moment the spray gun is closed is determined as the interruption moment.

[0184] Determining the interruption time based on the actual opening and closing status of the spray gun can avoid ignoring the spray gun closing delay by relying solely on the robot's stopping time.

[0185] S6.2. Identify continuous qualified film-forming boundaries based on the interruption time and update process data, and form interruption boundaries;

[0186] The ground control console reads the actual film thickness corresponding to each trajectory position before the interruption time according to the execution order of the spraying trajectory, and determines the last trajectory position that is continuously within the target film thickness range as the end qualified position.

[0187] The ground control console reads the effective spray width from the construction configuration data and, based on the spray band marker corresponding to the qualified end position, reads the lateral direction of the spray band from the spray control information. Using the qualified end position as the center, the ground control console extends half the effective spray width to both sides along the lateral direction of the spray band, directly forming the interruption boundary.

[0188] For example, if the effective spray width is 30 cm, and the robot moves forward along the spraying belt, with position A being the last position where the actual film thickness is continuously acceptable, then a boundary line with a width of 30 cm is formed by extending 15 cm on each side of the spraying belt from position A as the center. One side of this boundary line represents the area where the coating has been confirmed to be acceptable, and the other side represents the area where the spraying has not yet been confirmed to be complete.

[0189] S6.3. Determine the unfinished spraying area based on the interruption boundary and collect the boundary film thickness to form the continuous spraying boundary data;

[0190] The ground control console reads the confirmed area range from the valid area confirmation data, and then, using the interruption boundary as the dividing line, deducts the area that has been continuously sprayed from the confirmed area range to form the incomplete spraying area.

[0191] Subsequently, the ground control console selects multiple film thickness detection locations along the interruption boundary and sends boundary film thickness detection information to the spraying robot. The spraying robot, carrying the film thickness detection component, sequentially arrives at each film thickness detection location, collects the corresponding actual film thickness, and sends it to the ground control console. The ground control console collects the actual film thicknesses according to the film thickness detection locations to form boundary film thickness data.

[0192] The ground control console reads the spatial resolution from the equipment parameters of the film thickness detection component and arranges each film thickness detection position along the interruption boundary at a spacing not greater than the spatial resolution, so that the detection range of each film thickness detection position continuously covers the interruption boundary, thereby reducing the possibility of missing local film thickness anomalies at the boundary.

[0193] The ground control console extracts the completion time of the unfinished spraying area from the status data corresponding to the area to be sprayed, and then subtracts the completion time from the current time to obtain the update waiting time. The update waiting time represents the total time that has elapsed from the completion of surface treatment of the unfinished spraying area to the time when it is ready to resume spraying.

[0194] When the update waiting time does not exceed the effective retention time, the ground control console will collect the interruption time, interruption boundary, unfinished spraying area and boundary film thickness data to form the resume spraying boundary data.

[0195] When the update waiting time exceeds the effective retention time, the unfinished spraying area will not directly enter the re-spraying process, and the ground control console will send re-processing information to the surface treatment robot.

[0196] After the surface treatment robot completes the reprocessing, it re-collects the surface state data and area location data corresponding to the areas that were not sprayed. The ground control console then performs valid judgment and location correspondence analysis in sequence to generate updated valid area confirmation data.

[0197] Once the spraying conditions for the unfinished area are met again, the ground control console re-collects the boundary film thickness data at the interruption boundary and replaces the original valid area confirmation data with the updated valid area confirmation data. The interruption time, the original interruption boundary, the updated unfinished spraying area, and the re-collected boundary film thickness data are then aggregated to form the updated resume spraying boundary data. If the spraying conditions are not met again, no resume spraying boundary data is generated.

[0198] S7. Based on the spraying adjustment data and the continuous spraying boundary data, perform continuous spraying planning and generate continuous spraying control information to control the spraying robot to perform continuous spraying from the continuous spraying boundary to form a spraying result.

[0199] The follow-up spray planning is used to determine the follow-up spray range based on the interruption boundary, the unfinished spraying area, and the boundary film thickness status, and to configure the follow-up spray parameters in conjunction with the spraying adjustment data.

[0200] S7.1 Perform a connection range analysis on the continuous spray boundary data to form continuous spray trajectory data;

[0201] S7.1.1 Extract the interrupted boundary, incomplete spraying area and boundary film thickness data from the continuous spraying boundary data;

[0202] The three items respectively indicate the actual end point of spraying, the area that still needs to be sprayed, and the actual film thickness at the junction.

[0203] S7.1.2 Perform film thickness extreme value extraction on the boundary film thickness data to obtain the minimum film thickness and the maximum film thickness;

[0204] The ground control console compares the actual membrane thicknesses in the boundary membrane thickness data, extracts the minimum and maximum values, and obtains the minimum and maximum membrane thicknesses.

[0205] Extreme values ​​of film thickness can directly identify local thinning and thickening at the boundary, avoiding the average value from masking local anomalies.

[0206] S7.1.3 Obtain the target film thickness range, compare the minimum and maximum film thicknesses with the target film thickness range, and determine the overlap width;

[0207] The ground control console obtains the target membrane thickness range, initial overlap width, and allowable overlap width range from the construction configuration data.

[0208] When the minimum film thickness is lower than the lower limit of the target film thickness range, it indicates that there is insufficient film thickness at the interruption boundary. The ground control console will determine the upper limit of the allowed overlap width range as the overlap width.

[0209] When the minimum film thickness is not lower than the lower limit of the target film thickness range and the maximum film thickness is higher than the upper limit of the target film thickness range, it indicates that there is no insufficient film thickness at the interruption boundary but there is excessive film thickness. The ground control console will determine the lower limit of the allowed overlap width range as the overlap width.

[0210] When both the minimum and maximum membrane thicknesses are within the target membrane thickness range, the ground control console determines the initial overlap width as the overlap width.

[0211] For example, in this embodiment, the target film thickness ranges from 280 micrometers to 320 micrometers, the initial overlap width is 5 centimeters, and the allowable overlap width ranges from 3 centimeters to 8 centimeters.

[0212] For example, the actual film thicknesses at multiple detection locations at the interruption boundary were 255 μm, 268 μm, 285 μm, and 300 μm, respectively, with the minimum film thickness being 255 μm, which is lower than the lower limit of the target film thickness range, indicating insufficient film thickness at the interruption boundary. In this embodiment, the overlap width is increased from 5 cm to 8 cm to ensure that the subsequent spray coating covers the areas with insufficient film thickness.

[0213] For example, the actual film thicknesses at multiple detection locations at the interruption boundary were 290 μm, 310 μm, 326 μm, and 342 μm, respectively. The minimum film thickness was not lower than the lower limit of the target film thickness range, and the maximum film thickness was higher than the upper limit of the target film thickness range, indicating that there was no film thickness deficiency but rather film thickness excess at the boundary. In this embodiment, the overlap width was reduced from 5 cm to 3 cm to reduce repeated coverage of locations with excessive film thickness.

[0214] When the actual film thicknesses at multiple detection locations are 288 μm, 300 μm, 310 μm and 318 μm respectively, the minimum and maximum film thicknesses are both within the target film thickness range, so an initial overlap width of 5 cm is adopted.

[0215] S7.1.4 Determine the starting point and connection trajectory of the continued spraying based on the interruption boundary and the unfinished spraying area;

[0216] The ground control console determines the boundary reference point at the intersection of the interruption boundary and the original spraying strip, and then extends the overlap width from the boundary reference point to the completed spraying area in the opposite direction of the original spraying strip, and determines the extended trajectory position as the starting point for continued spraying.

[0217] Starting from the point of continued spraying, the ground control console crosses the interruption boundary along the original spraying zone and enters the unfinished spraying area. Then, it generates a connecting trajectory to cover the unfinished spraying area according to the original spraying plan.

[0218] S7.1.5. Collect the continuous spraying starting point, connection trajectory, and overlap width to form continuous spraying trajectory data;

[0219] The ground control console records the start point of the subsequent spray, the connection trajectory, and the overlap width into the same log, forming the subsequent spray trajectory data. The subsequent spray trajectory data clarifies where the connection spray starts, along which path it proceeds, and how much coverage is at the boundary, which can reduce missed sprays and coating buildup caused by fixed connection ranges.

[0220] S7.2. Configure the continuous spraying parameters on the spraying adjustment data and continuous spraying trajectory data to generate continuous spraying control information;

[0221] The ground control console extracts the interruption time from the continuous spray boundary data and arranges each spray adjustment data according to the formation time. The spray adjustment data whose formation time is no later than the interruption time and is closest to the interruption time is determined as the target spray adjustment data.

[0222] Next, read the control status from the target spraying adjustment data. When the control status is in parameter correction state, read the corresponding adjustment parameter as the continue spraying parameter; when the control status is in parameter hold state, read the corresponding current spraying parameter as the continue spraying parameter.

[0223] Then, the continuous spraying parameters are associated with the continuous spraying start point, connection trajectory, and overlap width in the continuous spraying trajectory data to generate continuous spraying control information.

[0224] S7.3. Control the continuous spraying according to the continuous spraying control information and perform result verification to form the spraying result;

[0225] The ground control console sends the continuous spraying control information to the painting robot. The painting robot moves to the continuous spraying starting point and performs continuous spraying along the connection trajectory according to the continuous spraying parameters in the continuous spraying control information, completing the spraying of the unfinished areas.

[0226] During the continuous spraying process, the spraying robot records the spraying tape markings, actual trajectory positions, spray gun opening and closing status, and actual film thickness according to a fixed collection cycle. It then collects the data according to the collection time to form continuous spraying execution data, and sends the continuous spraying execution data to the ground control console.

[0227] After the spraying is completed, the ground control console extracts the spraying band marker, actual trajectory position, spray gun opening and closing status, and actual film thickness from the spraying process data, update process data, and continued spraying execution data, and collects them according to the collection time and spraying band marker; when there are duplicate records for the same trajectory position, the record with the later collection time is retained to form a complete spraying execution record.

[0228] The ground control console filters the actual trajectory positions of the spray guns in the on state from the complete spraying execution record, and connects the actual trajectory positions within the same spraying zone according to the spraying zone identifier and the collection time to form the actual spraying trajectory.

[0229] The ground control console extends the effective spray width by half on both sides of the corresponding spray band, with each actual spray trajectory as the center, to form the spray coverage area corresponding to each actual spray trajectory. The spray coverage areas are then merged to form the actual spray coverage area.

[0230] The ground control console subtracts the actual spraying coverage from the area range in the valid area confirmation data to obtain the uncovered locations; the portion of the actual spraying coverage that exceeds the area range is identified as the out-of-bounds coverage location.

[0231] The ground control console checks whether each actual trajectory position where the spray gun is in the on state in the complete spraying execution record has a corresponding actual film thickness record. The actual trajectory position where no actual film thickness record is found is the position where the actual film thickness record is missing. Then, each actual film thickness is compared with the target film thickness range, and the trajectory position where the actual film thickness is not within the target film thickness range is determined as the film thickness non-compliant position.

[0232] When there are no uncovered or over-boundary covered locations, each actual trajectory location has a corresponding actual film thickness record, and each actual film thickness is within the target film thickness range, the ground control console will collect the area identification and spraying completion status to form the spraying result.

[0233] If there is at least one of the following: uncovered location, over-boundary coverage location, location with missing actual film thickness record, or location with unqualified film thickness, the ground control console will collect the corresponding location and the incomplete spraying status to form the spraying result.

[0234] By determining the interruption boundary based on the continuous qualified film formation state and determining the overlap width in combination with the boundary film thickness, the spraying robot can perform continuous spraying across the interruption boundary according to the continuous spraying parameters, which helps to reduce missed spraying, excessive repeated coverage and sudden changes in film thickness at the interruption position. By combining the actual spraying trajectory, effective spray width and actual film thickness to verify the execution results, the coverage integrity, spraying range and film thickness status of the area to be sprayed can be confirmed at the same time.

[0235] like Figure 2 As shown, this invention confirms the area to be sprayed by combining surface roughness, surface moisture content, and effective holding time; confirms the spraying range by unified coordinate conversion and positioning matching deviation verification; forms spraying adjustment data by combining spray gun status and actual film thickness; and determines the continuous spraying trajectory and overlap width based on the continuous qualified film boundary and boundary film thickness. This can improve the effectiveness of confirming the area to be sprayed, corresponding the spraying range, controlling the film thickness, and interrupting the connection.

[0236] The embodiments of the present invention described above are subject to modification and change of method by those skilled in the art without departing from the embodiments and broader aspects of the present invention. The appended claims are intended to include all such modifications and changes of method that do not depart from the present invention.

[0237] Those skilled in the art should understand that the embodiments of the present invention can be implemented using a pure hardware architecture, a pure software architecture, or an integrated hardware and software architecture. The present invention can be prepared as a computer program product, which can be stored in various non-volatile computer-readable storage media, including but not limited to solid-state drives, flash memory chips, mobile storage devices, optical discs, cloud storage servers, and other standardized storage media, and is not limited to traditional storage media.

[0238] Based on the foregoing description in conjunction with the accompanying drawings, those skilled in the art will understand that the embodiments of this application can also be implemented by software programs. Therefore, this application also provides a computer-readable storage medium. This computer-readable storage medium stores computer-readable instructions thereon, which, when executed by one or more processors, implement the method described above in conjunction with the accompanying drawings.

[0239] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0240] It should be noted that although the operations of the method of this application are described in a specific order in the accompanying drawings, this does not require or imply that these operations must be performed in that specific order, or that all the operations shown must be performed to achieve the desired result. On the contrary, the steps depicted in the flowchart can be performed in a different order. Additionally or alternatively, certain steps may be omitted, multiple steps may be combined into one step, and / or one step may be broken down into multiple steps.

[0241] It should be understood that when the terms "first," "second," "third," and "fourth," etc., are used in the claims, specification, and drawings of this application, they are used only to distinguish different objects and not to describe a specific order. The terms "comprising" and "including" as used in the specification and claims of this application indicate the presence of the described features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or collections thereof.

[0242] It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application. As used in this specification and claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in this specification and claims refers to any combination and all possible combinations of one or more of the associated listed items, and includes such combinations.

[0243] Although the embodiments of this application are described above, the content is merely an example adopted for the purpose of facilitating understanding of this application and is not intended to limit the scope and application scenarios of this application. Any person skilled in the art described in this application may make any modifications and changes in the form and details of the implementation without departing from the spirit and scope disclosed in this application, but the scope of patent protection of this application shall still be determined by the scope defined in the appended claims.

Claims

1. A robot collaborative control method for spraying coating on the surface of bridge piers in water-prone areas, characterized in that, include: The surface condition data and location data of the processing area collected by the surface treatment robot are acquired, and a valid judgment is performed to form the data of the area to be sprayed. Acquire the on-site location data of the painting robot, perform location correspondence analysis on the data of the area to be painted, and form valid area confirmation data; Based on the valid area confirmation data, the spraying plan is executed, spraying control information is generated to control the spraying robot to spray the area to be sprayed, and spraying process data is collected. Perform status analysis on the spraying process data to generate spraying adjustment data; Spraying is controlled based on the spraying adjustment data to generate updated process data; Interruption boundaries are identified from the update process data to form continuous spray boundary data; Based on the spraying adjustment data and the continuous spraying boundary data, the continuous spraying plan is executed, and continuous spraying control information is generated to control the spraying robot to perform continuous spraying from the continuous spraying boundary to form the spraying result.

2. The robot cooperative control method according to claim 1, characterized in that, The surface condition data and location data of the treatment area collected by the surface treatment robot are acquired, a valid determination is performed, and the data of the area to be sprayed is formed, including: The surface state of the processing area collected by the surface treatment robot is obtained and aggregated according to the processing area to form state data; Obtain the boundary of the processing area and perform coordinate unification processing to form regional location data; The status data is evaluated for validity and associated with the regional location data to form the area to be sprayed data.

3. The robot cooperative control method according to claim 2, characterized in that, Perform a valid determination on the status data and associate it with the area location data to form the area data to be sprayed, including: Obtain construction configuration data and extract the allowable range of roughness and the allowable range of surface moisture content; Surface roughness, surface moisture content, and processing completion time are extracted from the state data. Obtain the current time and the effective hold time, and calculate the waiting time between the current time and the processing completion time; When the surface roughness is within the allowable range, the surface moisture content is within the allowable range, and the waiting time does not exceed the effective holding time, the area location data is associated to form the area data to be sprayed.

4. The robot cooperative control method according to claim 1, characterized in that, Acquire the on-site location data of the painting robot, perform location correspondence analysis on the data of the area to be painted, and generate valid area confirmation data, including: The system acquires on-site structural features of the bridge piers collected by the spraying robot and performs positioning matching to generate on-site location data. A location correspondence analysis is performed on the data of the area to be sprayed and the on-site location data to form valid area confirmation data.

5. The robot cooperative control method according to claim 4, characterized in that, Perform location correspondence analysis on the data of the area to be sprayed and the on-site location data to form valid area confirmation data, including: Extract the region location data from the area to be sprayed data, and extract the position, posture and positioning matching deviation of the spraying robot from the on-site location data; Based on the position and posture of the painting robot, coordinate conversion is performed on the area position data to form on-site area position data; Obtain the allowable positioning matching deviation. When the positioning matching deviation does not exceed the allowable positioning matching deviation, collect the on-site area location data to form valid area confirmation data.

6. The robot cooperative control method according to claim 1, characterized in that, Perform state analysis on the spraying process data to generate spraying adjustment data, including: Perform a spraying state difference analysis on the spraying process data to generate spraying state deviation data; Parameter correspondence analysis is performed on the spraying state deviation data to generate spraying adjustment data.

7. The robot cooperative control method according to claim 6, characterized in that, Perform parameter correspondence analysis on the spraying state deviation data to generate spraying adjustment data, including: Extract distance deviation, angle deviation, and speed deviation from the spraying state deviation data; Perform deviation conversion on the distance deviation, angle deviation, and speed deviation to determine the corresponding adjustment amount; Extract the insufficient film thickness and excessive film thickness from the spraying state deviation data; Based on the pre-stored spraying calibration table, perform parameter matching for insufficient film thickness and excessive film thickness to determine the parameter adjustment amount; The control state is determined based on the spraying state deviation data; when at least one deviation exists, the adjustment starting point is determined based on the position of the first deviation trajectory, and the current spraying parameters are corrected according to the adjustment amount of each parameter; when none of the deviations exist, the current spraying parameters are used to form spraying adjustment data.

8. The robot cooperative control method according to claim 1, characterized in that, Identifying interruption boundaries from the update process data to form continued spray boundary data includes: The interruption status is identified during the update process to determine the interruption time. Based on the interruption time and update process data, continuous qualified film-forming boundaries are identified, and interruption boundaries are formed; Based on the interruption boundary, the unfinished spraying area is determined and the boundary film thickness is collected to form the continuous spraying boundary data.

9. The robot cooperative control method according to claim 1, characterized in that, Based on the spraying adjustment data and the continuous spraying boundary data, continuous spraying planning is performed to generate continuous spraying control information, thereby controlling the spraying robot to perform continuous spraying from the continuous spraying boundary to form the spraying result, including: Perform a connection range analysis on the continuous spray boundary data to form continuous spray trajectory data; Continuous spraying parameter configuration is performed on the spraying adjustment data and continuous spraying trajectory data to generate continuous spraying control information; Based on the continuous spray control information, the continuous spraying is controlled and the result is verified to form the spraying result.

10. The robot cooperative control method according to claim 9, characterized in that, Perform a connection range analysis on the continuous spray boundary data to form continuous spray trajectory data, including: Extract the interruption boundary, incomplete spraying area, and boundary film thickness data from the continuous spraying boundary data; Perform film thickness extremum extraction on the boundary film thickness data to obtain the minimum film thickness and the maximum film thickness; Obtain the target film thickness range, compare the minimum and maximum film thicknesses with the target film thickness range, and determine the overlap width; The starting point and connection trajectory for continued spraying are determined based on the interruption boundary and the unfinished spraying area; The continuous spraying start point, connection trajectory, and overlap width are collected to form continuous spraying trajectory data.

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