Waterwork surface coating robot for reactive two-component material and control method

Abstract

The application discloses a hydraulic surface coating robot for reactive two-component material and a control method. The robot comprises a moving platform, a mechanical arm, a two-component material supply circuit, a mixing valve and a controller. The method automatically identifies a hydraulic area to be repaired and divides vertical operation strips, draws a retention control body containing a mixing chamber and a material distribution area, calculates the volume of the mixed material section according to a formula and calculates the remaining operation time in real time, determines the strip access according to the curing time of the material, and divides the operation interruption into two types of boundaries and current positions, matches the mixing valve disposal scheme after shutdown, and differentiates the lap pretreatment according to the shutdown type when the operation is resumed. The application precisely controls the curing risk of the mixed material, reduces the pipeline blockage and coating joint defects, and traces the data in the whole construction process, and is suitable for the automatic repair operation of the concrete epoxy mortar of the spillway of a hydropower station.

Description

Technical Field

[0001] This invention belongs to the technical fields of automated repair of hydraulic structures, intelligent robotic coating construction, and precise feeding control of reactive two-component repair materials. It relates to a robot and method for coating hydraulic surfaces with reactive two-component materials. Background Technology

[0002] The concrete walls of spillways and stilling basins in hydropower stations are subject to long-term erosion from water flow and sediment, resulting in peeling, cracks, and other damage. Automated two-component epoxy mortar is commonly used for repair. However, the two-component materials have a fixed workable time after mixing. Prolonged retention of the mixture can lead to solidification and blockage of pipes and mixing components. Existing coating equipment suffers from two major drawbacks: First, existing equipment cannot quantitatively track the real-time quantity and retention time of the mixture in segments. It relies solely on estimating the duration of the entire operation to roughly assess the risk of solidification. For ultra-long hydraulic facades, only whole-segment operations are possible. If the mixture solidifies beyond the allotted time, it easily clogs the mixing valves, leading to frequent equipment cleaning and replacement. Second, sudden shutdowns during construction lack standardized, layered handling logic. There are no differentiated closing procedures for boundary shutdowns or mid-operation shutdowns. Shutdown locations are prone to thick coating edges and material accumulation defects. Furthermore, there are no corresponding pre-treatment schemes for joint breaks, resulting in poor quality of repaired coating seams. Additionally, various operational and defect data during construction cannot be fully archived and traced, making it difficult to meet the quality acceptance requirements of water conservancy projects. Summary of the Invention

[0003] The purpose of this invention is to provide a control method for a hydraulic surface coating robot for reactive two-component materials, which solves the construction problems of hydraulic two-component reactive coating robots: the mixture has a limited shelf life after mixing and is prone to clogging; shutdown can easily result in thick edges of the coating and defects at the joints; there is no standardized breakpoint continuation scheme; existing methods rely solely on the total time to predict the curing risk; and the construction quality is poor and the data cannot be traced.

[0004] To solve the above problems, the technical solution of the present invention is as follows: A hydraulic surface coating robot for reactive two-component materials includes a robot chassis, a robotic arm, a scraping tool, a component A feeding circuit, a component B feeding circuit, a mixing valve, and a controller. The mixing valve is located at the front end of the scraping tool. Both the component A and component B feeding circuits include a material tank, a metering pump, and a feed / return switching valve. Each circuit has an output branch and a return branch; the output branch connects to the mixing valve, and the return branch connects to the corresponding material tank. The robot chassis carries the robotic arm, the two feeding circuits, and the controller. The scraping tool is fixed at the end of the robotic arm, which is equipped with a torque sensor, a positioning module, and a camera for capturing morphological data. The scraping tool has a contact pressure detection module. The controller is electrically connected to the robot chassis, robotic arm, metering pump, feed / return switching valve, mixing valve, contact pressure detection module, and camera.

[0005] Furthermore, the mixing valve is equipped with a temperature sensor, which is connected to the input terminal of the controller.

[0006] Furthermore, the robot chassis is a tracked robot chassis, and a tilt sensor is mounted on the chassis. The tilt sensor is connected to the input terminal of the controller.

[0007] A robotic control method for coating hydraulic surfaces with reactive two-component materials includes the following steps: S1. The camera captures images / point clouds of the hydraulic wall surface and identifies the area to be repaired; it divides multiple work strips based on tool width, overlap, and the reachability of the robotic arm; it generates candidate parking locations and plans transfer paths, and generates work permits after verifying accessibility. S2. Delineate the retention area of ​​the mixture, divide the mixture into sections according to the sampling cycle, and record the mixing time, volume, temperature and load of each section; deduct the remaining volume of the mixture section by section as the paint is scraped off, and correct the predicted curing time of each mixture section according to the temperature, pipeline pressure and driving load, and take the shortest predicted time as the overall remaining operable time. S3. Predict the maximum residence time of the mixture throughout the entire operation of a single strip. When the maximum residence time plus the preset margin is less than or equal to the operable time after temperature correction, and the raw material inventory meets the strip's material requirements, release the operating strip and connect the output branch. If the access conditions are not met, split the strip into multiple segments along the height and recalculate until the segments meet the constraints. S4. During construction, continuously update the remaining operable time, calculate the time taken to reach the boundary stop position and the required material quantity at the boundary; after triggering an interruption event, verify the overall safety status of the machine; if the machine is allowed to travel to the boundary, and the time and material conditions are met, execute boundary closing: calculate the supplementary material supply and continuously mix and discharge the material, drive the tool to the boundary stop position, switch the material supply circuit to the return branch before and after reaching the stop position, shut down the mixing valve, and generate a boundary stop record; if the boundary closing conditions are not met, execute current position closing: immediately switch the circuit to the return branch to stop mixing, and after safety is met, control the tool to collect the material and lift the blade, and generate a current position stop record; S5. Determine the handling method based on the estimated pause duration, remaining operable time after shutdown, and pipeline load; if the pause duration is short and the load has not reached the blockage threshold, retain the mixing valve; otherwise, discharge the mixture or replace the mixing valve. S6. Retrieve shutdown records and match corresponding continuation rules. For boundary shutdowns, construction begins from the starting point of the adjacent strip. For shutdowns at the current location, the coating starts from the shutdown point and retreats a preset distance in the opposite direction. Collect the morphology of the shutdown location. If defects exceed the standard, clean the overlapping area. After construction is completed, inspect coating defects. Defective areas generate rework units. Archive and store all construction data throughout the process.

[0008] Furthermore, in step S2, when dividing the mixture into segments according to the sampling period, the formula for calculating the mixing volume of a single segment is as follows: ,in For the volume of the mixing section, The instantaneous flow rate of component A is... For the instantaneous flow rate of component B, The sampling period.

[0009] Furthermore, in S2, the flow meter is used for direct reading; the amount of mixture flowing out of the mixture retention area is calculated by the coating area, and the two sets of values ​​are cross-verified.

[0010] Furthermore, in S4, the boundary finishing material supply equals the boundary material requirement. The amount of unscraped mixture in the mixture retention area is a non-negative value. The supply flow of components A and B is allocated according to the material ratio. After the cumulative discharge reaches the set value, the return branch is switched.

[0011] Furthermore, when executing the S4 operation interruption sub-mode closing steps, the interruption trigger conditions under the transfer and walking conditions include obstacle distance, chassis tilt angle, and communication status.

[0012] Furthermore, when performing the S5 mixing valve shutdown procedure, while maintaining the mixing valve in operation, a trial discharge test is performed before resuming operation. The material supply is restarted after the pressure and load return to the baseline range.

[0013] Furthermore, when executing the S6 breakpoint continuation and quality control steps, after all strip construction is completed, the mixture operation data, shutdown records, and defect handling records are automatically stored.

[0014] The beneficial effects of this invention are as follows: 1. This invention delineates the mixture retention area, calculates the mixture volume in segments through sampling cycles, and dynamically corrects the curing time of each segment of the mixture in real time. The shortest predicted curing time is used as the remaining operable time of the whole machine. This invention accurately quantifies the curing risk of all mixtures in pipelines, mixing valves, and scraping tools, abandoning the traditional method of roughly predicting the overall time. It significantly reduces the probability of curing blockage in mixing valves and discharge pipelines, and reduces the amount of manual disassembly and cleaning work.

[0015] 2. This invention sets up an access judgment mechanism for the working strip. If the maximum retention time of the mixture in a single strip exceeds the material's operable time limit, it automatically splits into short sections for construction. This is suitable for the construction of the side walls of high-sized hydraulic spillways and is not constrained by the limited operable time of the two-component materials, thus expanding the applicable construction range of the equipment.

[0016] 3. The operation interruption is handled by two modes: boundary finishing and current position finishing. Under the conditions of meeting time, material and safety requirements, the work can be carried out directly to the top of the strip before stopping the machine, which reduces coating accumulation and thick edge defects caused by mid-operation stoppage; the boundary finishing accurately calculates the amount of supplementary material supply, avoids excessive material output and waste of repair materials, and reduces the cost of rework later.

[0017] 4. After shutdown, the handling plan for the mixing valve should be determined by combining the remaining operable time, the estimated downtime, and the pipeline load. For short-term shutdowns, the internal mixture can be retained. For long-term shutdowns, the material should be discharged or the mixing valve should be replaced. The maintenance plan should be matched with the on-site working conditions to avoid unnecessary manual operation.

[0018] 5. Based on the type of shutdown, differentiated continuation construction rules are matched. When the machine stops at the boundary, it directly overlaps with the next strip. When the machine stops in the middle, it reverses and retreats to reserve an overlap cleaning area. The camera is used to identify coating defects at the overlap and the protrusions are cleaned with a scraper tool. The construction standards at the break point are unified to improve the overall flatness and construction quality consistency of the hydraulic repair coating.

[0019] 6. The machine is equipped with a camera, positioning module, and multiple sensors working together to automatically identify damaged areas on the wall and autonomously plan the work strip and chassis transfer path to achieve unmanned positioning construction; the machine automatically stores the mixed material operation data, shutdown records, and defect handling records throughout the construction process. The data can be stored and retrieved for a long time, meeting the quality traceability and acceptance standards for the entire process of water conservancy projects. Attached Figure Description

[0020] The invention will be further described below with reference to the accompanying drawings: Figure 1 This is a three-dimensional structural diagram of the present invention. Figure 2 This is a schematic diagram of the overall structure of the present invention. Figure 3 This is a schematic diagram of the connection structure between the various electrical components in this invention. Figure 4 This is a schematic diagram of the process of the present invention. Figure 5 This is a schematic diagram of the coating process of the present invention.

[0021] In the diagram: 1. Robot chassis; 2. Component A material container; 3. Component B material container; 4. Robotic arm; 5. Positioning module; 6. Mixing valve; 7. Scraper tool; 8. Camera; 9. Tilt sensor; 10. Metering pump; 11. Feed / return switching valve; 12. Temperature sensor; 13. Contact pressure detection module. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] like Figure 1 and 2 As shown, the hydraulic surface coating robot for reactive two-component materials includes a robot chassis 1, a robotic arm 4, a scraping tool 7, two independent feeding circuits, a mixing valve 6, and a controller.

[0024] The mixing valve 6 is mounted at the front end of the scraping tool 7. It is the physical location where the two raw materials, component A and component B, first come into contact and mix. After the raw materials are mixed here, they flow to the fabric application area.

[0025] The A-component feeding circuit and the B-component feeding circuit have the same structure. Each circuit includes a material storage tank, a metering pump 10 for quantitative material delivery, and a feed / return switching valve 11 for switching between feeding and recirculation. Each pipeline branches into two branches. The output branch is directly connected to the feed inlet of the mixing valve 6, and the return branch is reversing and connected to its corresponding material tank. The flow direction of the raw materials is switched by switching the valve 11. When the equipment is stopped, the unmixed single component can be returned and recovered to avoid waste of raw materials, while preventing the A and B components from continuously contacting and generating excess mixture.

[0026] The robot chassis 1 serves as the main support for the entire machine, supporting the robotic arm 4, two sets of feeding circuits, and the controller on the chassis frame. The chassis has the ability to move and drive, and can autonomously complete site relocation and adapt to the location switching needs of different working areas in hydraulic engineering.

[0027] The base of the robotic arm 4 is fixedly installed on the robot chassis 1. The end of the robotic arm 4 is equipped with a scraping tool 7 and a camera 8. The robotic arm 4 body integrates a torque sensing module and a spatial positioning module 5. The torque sensor collects the load changes of the robotic arm 4 in real time, and the positioning module 5 provides real-time feedback of the three-dimensional coordinates of the scraping tool 7 to control the scraping path and working pressure. The camera 8 acquires the volume of the mixture inside the cloth area and the outline of the wall coating in real time.

[0028] The mixed material is first stored in the fabric area and then applied to the concrete wall. The squeegee is equipped with a contact pressure detection module 13, which provides real-time feedback on the adhesion between the squeegee 7 and the hydraulic wall, ensuring that the coating thickness is uniform and controllable.

[0029] The controller establishes electrical signal connections with the robot chassis 1 drive component, the robotic arm 4 drive component, two sets of metering pumps 10, the feed / return switching valve 11, the mixing valve 6, and all sensor modules through multiple sets of electrical lines. All data collected and action commands executed by the whole machine are uniformly sent and received by the controller, realizing integrated collaborative operation of the equipment.

[0030] Furthermore, a temperature sensor 12 is installed on the mixing valve 6 chamber. The temperature sensor 12 collects the real-time temperature of the mixed material after mixing, providing accurate temperature data support for the subsequent correction of the curing time of the mixed material, directly obtaining the true temperature of the mixed material, and improving the accuracy of the remaining operable time calculation.

[0031] Furthermore, the robot chassis 1 is equipped with a tilt sensor 9, which collects the horizontal tilt angle of the chassis in real time, so that the controller can obtain the chassis status in real time and provide data support for determining the safety of the operation. For example, if the tilt exceeds 20 degrees, the operation will stop.

[0032] A robot-based method for controlling the coating of reactive two-component materials on hydraulic surfaces includes the following steps: S1. After the equipment is started, the camera 8 on the scraping tool 7 collects images and point cloud data of the hydraulic spillway and stilling basin sidewall. The controller identifies areas waiting to be repaired, such as honeycomb, peeling, and cracks on the wall surface, by collecting the data, and maps the three-dimensional spatial coordinates to the operation coordinate system. Combining the actual working width of the scraping tool 7, the preset coating overlap amount, and the spatial movement range of the robotic arm 4, the large continuous repair area is automatically divided into multiple vertical, bottom-up construction strips. The top endpoint of each construction strip is set as the boundary stop position. Construction can be completed without interruption when the coating is completed at this point. The controller generates multiple sets of candidate parking positions, plans the transfer path of the robot chassis 1, and controls the chassis walking mechanism to move autonomously to the target parking point. At the same time, the accessibility of all work points of the robotic arm 4 and the stability coefficient of chassis support are checked. After all parameters meet the standards, a work permit signal is generated, and the raw material transportation preparation process is started.

[0033] S2. The controller delineates the complete mixture retention area. Along the mixture flow path, this area sequentially includes the mixing chamber inside mixing valve 6, the discharge channel, the discharge section of mixing valve 6, and the material distribution area at the front of the scraping tool 7. All mixed materials are included in the control scope to avoid missing any residual material in pipelines or tools, which could lead to misjudgments of solidification. The controller sets a fixed sampling period. Each sampling period independently generates a set of mixture segments. The mixing volume of a single segment is strictly calculated according to the formula, representing the volume of the mixture segment generated in the current sampling period, the instantaneous flow rate of component A, the instantaneous flow rate of component B, and the duration of a single sampling period. The controller simultaneously records the mixing time of the mixture segment, the calculated mixing volume, the real-time temperature of the mixture, and the drive load of the feed pump and mixing valve 6. During the scraping application process, the mixture continuously adheres to the hydraulic wall surface, forming... The coating system uses a controller to continuously monitor the total volume of the mixture that has flowed out of the retention area and been coated. Starting from the earliest generated section, the controller subtracts the remaining volume from each section. If the remaining volume of a section decreases to zero, it is determined that the section has completely left the retention area and is no longer included in the curing time calculation. The controller uses real-time temperature parameters to shorten the curing time of the mixture under high-temperature conditions. It also further corrects the predicted curing time of each section by considering changes in pipeline pressure and drive load. It iterates through all sections that have not flowed out of the retention area and extracts the shortest predicted curing time as the overall remaining operable time of the mixture. This serves as the core basis for subsequent strip access and interruption handling, accurately quantifying the curing risk of the mixture and avoiding the blockage defects caused by the current method of roughly predicting the overall construction time.

[0034] S3. The controller, combining the total length of a single working strip, the scraping speed of the robotic arm 4, and the preset material flow curve, calculates the longest residence time of the mixture in the mixture retention area during the entire strip construction process. When the longest residence time plus the preset safety margin is still less than the temperature-corrected material operability time, and the material inventory in the hopper can meet the total coating demand of the entire strip, the controller releases the working strip and controls the feed / return switching valve 11 to open the output branch, allowing components A and B to enter the mixing valve 6 to begin mixing. If the calculated maximum residence time exceeds the material's allowable range, the controller divides the entire strip into multiple short working segments along the vertical height of the working strip. Segment stop positions are set at the junctions of the segments, with reserved space for lifting the blade and reverse overlapping construction. The maximum residence time of each segment is calculated segment by segment until the segment meets the access constraints before segment release for construction. This method is suitable for ultra-long hydraulic sidewall construction scenarios and is not limited by the material's limited operability time.

[0035] S4. During the vertical scraping process, the remaining operable time of the mixture is continuously updated. The total time to reach the boundary stop position is calculated based on the straight-line distance from the current scraping point to the top boundary stop position, the preset travel speed, and the time taken for the final blade lifting action. The total amount of paint required for the finishing stage, i.e., the boundary material requirement, is calculated based on the remaining unpainted coating area, the target coating thickness, and the material volume correction factor. Various sensor data are continuously collected during equipment operation. If any parameter exceeds the safety threshold, an operation interruption event is triggered. The controller immediately verifies the physical safety status of the entire machine. If the robotic arm 4 and chassis have no risk of overturning or instability, and the total time to reach the boundary plus the safety margin is less than the remaining operable time, and the raw material inventory meets the boundary material requirement, then the boundary finishing operation is performed: the total amount of additional continuously supplied mixture is calculated, and A is allocated according to the material ratio. The B component output flow continuously mixes and discharges, driving the robotic arm 4 to move the scraping tool 7 at a constant speed to the top of the strip. Before and after reaching the boundary point, the two sets of feeding circuits are switched to the return branch simultaneously, stopping the metering pump 10 from feeding and the mixing valve 6 from stirring. The system automatically stores the boundary stop record, fully recording the strip number, stop coordinates, and overlap length. Boundary finishing can reduce coating thickness and material accumulation defects caused by mid-process stoppage. If safety conditions are not met, curing time is insufficient, or raw material inventory is short, the controller immediately switches the A / B components to the return branch, terminating the mixing output of the mixture. After the chassis and robotic arm 4 stabilize, the scraping tool 7 is controlled to make small reciprocating movements to consume the residual material in the front material distribution area. The unloading blade is lifted and detached from the concrete wall, generating the current position stop record, quickly isolating unmixed raw materials, and reducing the probability of solidification and blockage of the mixing valve 6 and the pipeline.

[0036] S5. The system reads the remaining operable time of the mixture at the time of shutdown and the estimated downtime, and combines the pipeline pressure and the load of the mixing valve 6 to comprehensively determine the handling plan. If the estimated downtime is less than the remaining operable time minus the preset safety margin, and the pipeline pressure and the load of the mixing valve 6 have not reached the critical threshold for blockage, it means that the mixture will not solidify in the short term, and the mixture inside the mixing valve 6 can be retained. If the downtime is too long and the load is close to the blockage threshold, the controller prompts the operator to drain the mixture inside the mixing valve 6 into the collection container, or directly disassemble and replace the mixing valve 6. The corresponding maintenance plan is matched according to the actual downtime and the state of the mixture to avoid ineffective manual cleaning operations and reduce the workload of equipment maintenance.

[0037] S6. The controller retrieves shutdown records to distinguish between two working conditions: boundary shutdown and current position shutdown, and matches the corresponding continuation construction rules. Boundary shutdown records correspond to the construction of the next strip, with the continuation starting point being the bottom start end of the adjacent strip, and a standard lateral overlap width is set. Current position shutdown records require the robotic arm 4 to retreat a preset distance along the original strip as the continuation starting point, reserving an overlap scraping area. Before starting recoating, camera 8 collects the coating outline at the shutdown position and identifies accumulation (such as mud or residual adhesive). When the accumulation range exceeds a preset threshold, the scraping tool 7 (such as a scraper) at the control end scrapes the overlap area to remove the protrusions and pushes before starting the scraping construction, unifying the construction standards at breakpoints and improving the overall quality consistency of the coating. After the complete strip construction is completed, the sensor inspects the coating surface, automatically marks the protruding areas, generates an independent rework unit, and all construction data is uniformly archived and stored, completely preserving the information of the entire construction process.

[0038] Furthermore, during the execution of step S2, there are two methods for collecting the instantaneous flow rates of component A and component B. The first is to directly read the values ​​from the pipeline flow meter, and the second is to estimate them by calculating the unit speed displacement of the screw pump, the real-time speed, and the factory calibration coefficient. A dual calculation method is set for the amount of mixed material flowing out of the mixed material retention area. On the one hand, it is indirectly calculated by multiplying the completed coating area, the target coating thickness, and the material volume correction coefficient. On the other hand, it is directly calculated by collecting the three-dimensional contour of the material distribution area by the end camera 8. The two sets of values ​​are cross-checked in real time to avoid the distortion of the remaining operable time calculation caused by the deviation of a single metering method, thereby improving the accuracy of mixed material control.

[0039] Furthermore, during the execution of step S4, the formula for calculating the supplementary material supply required at the boundary closing stage is: Supplementary material supply = Boundary material requirement If the amount of unscraped mixture in the mixture retention area is negative, the value is set to 0. The controller allocates the flow rate of components A and B in real time according to the standard ratio of the two-component materials. When the total amount of material discharged by metering pump 10 reaches the calculated set value of supplementary material supply, the feed / return valve is switched to the return branch synchronously or after a delay to accurately control the total amount of material discharged in the final stage, prevent excessive material discharge and waste of raw materials, and reduce the amount of rework for coating repair in the later stage.

[0040] Furthermore, during step S4, the equipment operates under two different conditions, with distinct interruption criteria: the first is the robot chassis 1 relocation and movement condition, where interruption is triggered by insufficient obstacle distance, chassis tilt exceeding a threshold, and equipment communication link interruption; the second is the parking coating construction condition, which, in addition to the relocation condition criteria, includes four additional detection indicators: outrigger load exceeding limits, robotic arm 4 torque load exceeding standards, abnormal end-wall contact pressure, and mixed material pipeline pressure exceeding standards. The controller compares the values ​​collected by various sensors with the corresponding safety thresholds in real time, quickly outputting an interruption judgment signal to comprehensively cover equipment, personnel, and coating quality safety risks.

[0041] Furthermore, in step S5, if it is determined that the mixture inside the mixing valve 6 should be retained, the test discharge detection process will be automatically started before the equipment resumes operation. The controller controls the metering pump 10 to output the mixture for a short time and collects the pipeline pressure and the driving load value of the mixing valve 6 in real time. Only when the pressure and load return to the normal temperature reference range, it is determined that the mixture has not been cured and blocked, and the material supply and coating operation can be officially restarted to prevent the internal locally cured residue from forming coating holes and protrusion defects with the coating.

[0042] Furthermore, in step S6, after the construction of a single or all work strips is completed, the controller automatically stores complete construction data, including the operation calculation data of the mixing section, various shutdown records, and coating defect handling records. All data is stored locally for a long time and can be uploaded to the cloud simultaneously. During the water conservancy project quality acceptance stage, all construction logs can be fully retrieved, realizing the traceability of data throughout the entire process of hydraulic engineering repair construction and meeting the requirements of water conservancy industry engineering quality acceptance specifications.

[0043] Example: This implementation case selects the concrete sidewall of the stilling basin of a hydropower station as the construction object. The repair material is HK-EQ two-component epoxy putty, with a standard weight ratio of A to B components of 4:1. The benchmark working time is 30 minutes at room temperature of 25℃. The effective working width of the squeegee tool is 0.1m, the standard overlap width of adjacent strips is 0.05m, and the target coating thickness is 3mm.

[0044] Step 1: Camera 8 collects complete point cloud data of the stilling basin sidewall. The controller identifies the damaged and defective areas of the wall and converts them to the working coordinate system. Combining the tool width, overlap amount, and movement range of the robotic arm 4, the 2m wide sidewall is automatically divided into 20 vertical working strips from bottom to top. A boundary stopping position is set at the top 1m of each strip. The controller generates multiple sets of candidate parking points, plans a straight transfer path, and controls the robot chassis 1 walking mechanism to autonomously move to the target parking position. The controller verifies that the robotic arm 4 can reach the target position throughout the entire process and that the chassis tilt angle meets the threshold, and generates a work permit signal.

[0045] Step 2: The controller reads the temperature of the mixture collected by the temperature sensor 12 of the mixing valve 6, and delineates the mixing chamber, discharge channel, discharge port of the mixing valve 6, and the material distribution area at the front end of the scraper as the mixture retention area; it starts the sampling cycle, and collects the flow rate of components A and B, mixture temperature, pipeline pressure, and load of metering pump 10 in real time each cycle, and generates and stores all parameters of the mixture segment in real time; during the construction process, it continuously counts the total volume of the scraped coating, deducts the remaining volume of the mixture segment segment by segment, updates the predicted remaining curing time of each mixture segment in real time, and extracts the minimum value as the remaining operable time of the whole machine; when the pipeline pressure continues to rise during the construction process, it automatically reduces the available time of the corresponding mixture segment, predicts the risk of curing blockage in advance, and uses a dual method to cross-verify the flow rate and residual volume to ensure the accuracy of the calculation.

[0046] Step 3: The controller calculates the maximum residence time of the mixture for the entire 2m strip application process as 22 minutes. After adding the preset safety margin, the total residence time is 23 minutes, which is less than the 30-minute baseline operable time at 25℃. Simultaneously, the raw material barrel has sufficient material for the entire strip's coating needs. The controller releases the first working strip, controlling the feed / return switching valve 11 to open the output branch. Components A and B enter the mixing valve 6 for mixing, initiating vertical scraping. If the strip height is adjusted to 1.5m, the calculated maximum residence time is 32 minutes. After adding the safety margin, this exceeds 30 minutes. The controller automatically divides the strip vertically into two 7.5m short working sections. After verifying the residence time of each section and confirming it meets the entry requirements, construction proceeds in sections.

[0047] Step 4: The robotic arm 4 drives the scraping tool 7 to scrape the material at a uniform speed from bottom to top, updating the remaining operable time in real time, and continuously calculating the remaining distance to the top of the strip, the time taken to reach it, and the amount of material required for boundary finishing. When the construction reaches a height of 1m, the sensor detects a falling concrete obstacle in front, triggering an operation interruption event. The controller verifies that the chassis is stable and the robotic arm 4 has no risk of tipping over. The remaining time to reach the top is calculated to be 4 minutes, plus a safety margin of 5 minutes, and the current remaining operable time is 12 minutes. The raw material inventory meets the boundary material requirement, and boundary finishing is performed: the volume of unscraped material in the mixed material retention area is calculated, and the boundary material requirement is reduced by the volume of unscraped material to obtain the additional supply. The metering pump 10 is controlled to continuously discharge material according to the 4:1 ratio, and the robotic arm 4 moves at a uniform speed to the top of the strip. After reaching the boundary point, the A and B component switching valves 11 are switched to the return branch, the mixing valve 6 is stopped, and the system stores the boundary stop recording.

[0048] If, during construction at a height of 1 meter, the load on one side of the robot chassis 1 exceeds the limit, triggering an interruption, the controller determines that it cannot stably advance to the top of the strip and immediately switches both material supply circuits to the return branch, terminating the mixing of the mixture. After the load on the outrigger returns to normal, the controller controls the scraping tool 7 to perform a small reciprocating motion to consume the residual material in the front material distribution area, releasing the pressure and lifting the blade away from the wall, generating a stop record for the current position. Different interruption judgment conditions are corresponding to the two working conditions of site transfer and parking, comprehensively ensuring equipment safety.

[0049] Step 5: After a boundary shutdown, the estimated downtime is 5 minutes. If the remaining operable time at the time of shutdown is 7 minutes, and the remaining time after deducting the safety margin is longer than the estimated downtime, and the pipeline pressure and the load on mixing valve 6 have not reached the blockage threshold, the controller will retain mixing valve 6. Before resuming operation, a trial discharge test will be initiated. Feeding will resume after the pressure and load return to the baseline range. If the estimated downtime is 10 minutes, exceeding the remaining operable time after deducting the safety margin, the controller will output a prompt, and the operator should drain the mixture inside mixing valve 6 into the collection container or directly replace mixing valve 6.

[0050] Step 6: This shutdown is a boundary shutdown record. The controller controls the robotic arm 4 to move to the bottom start of the second working strip, sets the standard lateral overlap width, and directly starts the recoating operation. If the shutdown is at a height of 1m at the current point, the robotic arm 4 retreats a preset distance along the strip as the starting point for the continuation work. The shape sensor collects the coating contour at the shutdown position, identifies the thick edge defect at the shutdown point exceeding the threshold, and scrapes the overlap area with the scraping tool 7 (e.g., a scraper) at the control end to remove the protrusions and pushes before starting the scraping construction. This unifies the construction standards at the breakpoints and improves the overall quality consistency of the coating. After the complete strip construction is completed, the sensor inspects the coating surface, automatically marks the protruding areas, generates an independent rework unit, and all construction data is uniformly archived and stored to completely preserve the information of the entire construction process.

[0051] The embodiments described in this specification are merely examples of implementations of the inventive concept. The scope of protection of this invention should not be considered as limited to the specific forms stated in the embodiments. The scope of protection of this invention also extends to equivalent technical means that can be conceived by those skilled in the art based on the inventive concept.

Claims

1. A robot for coating hydraulic surfaces with reactive two-component materials, characterized in that, The system includes a robot chassis, a robotic arm, a coating tool, a component A feeding circuit, a component B feeding circuit, a mixing valve, and a controller. The mixing valve is located at the front end of the coating tool. Both the component A and component B feeding circuits include a material tank, a metering pump, and a feed / return switching valve. Each circuit has an output branch and a return branch; the output branch connects to the mixing valve, and the return branch connects to the corresponding material tank. The robot chassis carries the robotic arm, the two feeding circuits, and the controller. The coating tool is fixed to the end of the robotic arm, which is equipped with a torque sensor, a positioning module, and a camera for capturing morphological features. The coating tool has a contact pressure detection module. The controller is electrically connected to the robot chassis, robotic arm, metering pump, feed / return switching valve, mixing valve, contact pressure detection module, and camera.

2. The hydraulic surface coating robot for reactive two-component materials according to claim 1, characterized in that, The mixing valve is equipped with a temperature sensor, which is connected to the input terminal of the controller.

3. The hydraulic surface coating robot for reactive two-component materials according to claim 1, characterized in that, The robot chassis is a tracked robot chassis, and a tilt sensor is mounted on the chassis. The tilt sensor is connected to the input terminal of the controller.

4. A control method for a hydraulic surface coating robot for reactive two-component materials according to any one of claims 1 to 3, characterized in that, Includes the following steps: S1. The camera captures images / point clouds of the hydraulic wall surface and identifies the area to be repaired; multiple work strips are divided based on tool width, overlap, and the reach of the robotic arm. Generate candidate parking locations and plan relocation routes, and generate work permits after verifying accessibility; S2. Delineate the retention area of ​​the mixture, divide the mixture into sections according to the sampling cycle, and record the mixing time, volume, temperature and load of each section; deduct the remaining volume of the mixture section by section as the paint is scraped off, and correct the predicted curing time of each mixture section according to the temperature, pipeline pressure and driving load, and take the shortest predicted time as the overall remaining operable time. S3. Predict the maximum residence time of the mixture throughout the entire operation of a single strip. When the maximum residence time plus the preset margin is less than or equal to the operable time after temperature correction, and the raw material inventory meets the strip's material requirements, release the operating strip and connect the output branch. If the access conditions are not met, split the strip into multiple segments along the height and recalculate until the segments meet the constraints. S4. During construction, continuously update the remaining operable time, calculate the time taken to reach the boundary stop position and the required material quantity at the boundary; after triggering an interruption event, verify the overall safety status of the machine; if the machine is allowed to travel to the boundary and the time and material conditions are met, perform boundary closing: calculate the supplementary material supply and continue mixing and discharging, drive the tool to the boundary stop position, switch the material supply circuit to the return branch before and after reaching the stop position, shut down the mixing valve, and generate a boundary stop record; if the boundary closing conditions are not met, perform current position closing: immediately switch the circuit to the return branch to stop mixing, and after safety is met, control the tool to collect material and lift the blade, and generate a current position stop record; S5. Determine the handling method based on the estimated pause duration, remaining operable time after shutdown, and pipeline load; if the pause duration is short and the load has not reached the blockage threshold, retain the mixing valve; otherwise, discharge the mixture or replace the mixing valve. S6. Retrieve shutdown records and match corresponding continuation rules. For boundary shutdowns, construction begins from the starting point of the adjacent strip. For shutdowns at the current location, the coating starts from the shutdown point and retreats a preset distance in the opposite direction. Collect the morphology of the shutdown location. If defects exceed the standard, clean the overlapping area. After construction is completed, inspect coating defects. Defective areas generate rework units. Archive and store all construction data throughout the process.

5. The control method for a hydraulic surface coating robot for reactive two-component materials according to claim 4, characterized in that, In step S2, when dividing the mixture into segments according to the sampling period, the formula for calculating the mixing volume of a single segment is as follows: ,in For the volume of the mixing section, The instantaneous flow rate of component A is... For the instantaneous flow rate of component B, The sampling period.

6. The control method for a hydraulic surface coating robot for reactive two-component materials according to claim 5, characterized in that, In S2, the flow meter is used for direct reading. The amount of mixed material flowing out of the mixed material retention area is calculated by the coating area, and the two sets of values ​​are cross-verified.

7. The control method for a hydraulic surface coating robot for reactive two-component materials according to claim 4, characterized in that, S4 Boundary Finishing Supplementary Material Supply = Boundary Material Requirement The amount of unscraped mixture in the mixture retention area is a non-negative value. The supply flow of components A and B is allocated according to the material ratio. After the cumulative discharge reaches the set value, the return branch is switched.

8. The control method for a hydraulic surface coating robot for reactive two-component materials according to claim 4, characterized in that, When performing the S4 operation interruption sub-mode closing steps, the interruption trigger conditions under the transfer and walking conditions include obstacle distance, chassis tilt angle, and communication status.

9. The control method for a hydraulic surface coating robot for reactive two-component materials according to claim 4, characterized in that, When performing the S5 mixing valve shutdown procedure, keep the mixing valve in operation and perform a test discharge test before resuming operation. Restart the material supply after the pressure and load return to the baseline range.

10. The control method for a hydraulic surface coating robot for reactive two-component materials according to claim 4, characterized in that, When executing the S6 breakpoint continuation and quality control steps, after all strip construction is completed, the mixture operation data, shutdown records, and defect handling records are automatically stored.

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