Full-automatic galvanizing implementation method in the field of material surface treatment technology

Abstract

The present application relates to a kind of material surface treatment technical field's full-automatic galvanization implementation method, it relates to material surface treatment technical field, the galvanization process parameter of different object is established as " automatic galvanization model", and through controller and RGV crane carry out data interaction, through model establishment, intelligent monitoring, collaborative control and post-processing optimization each step, realize the full automation of galvanization process, high refinement.

Description

Technical Field

[0001] This invention relates to the field of material surface treatment technology, specifically a fully automated zinc plating method in the field of material surface treatment technology. Background Technology

[0002] Hot-dip galvanizing for corrosion protection has been a technology for over 170 years. It involves immersing pre-treated metal components in molten zinc to form a zinc-iron alloy layer on the metal surface, thus providing corrosion protection. However, the production level of galvanizing plants in China is relatively backward, with outdated equipment. The vast majority of hot-dip galvanizing plants still rely on manual operation. This manual operation not only results in extremely high labor intensity for workers, but the zinc fumes generated during production also seriously harm the health of operators. Furthermore, it negatively impacts production capacity and product quality stability. Although some automated galvanizing production lines exist, such as those using RGV carts for material handling or controllers to automatically control some process parameters, they often lack differentiated and refined control strategies for different workpieces.

[0003] Publication No. CN111967768A, patent title: "Layout and Implementation Method of an n-type Hot-dip Galvanizing Two-in-One Automated Production Line System," while involving the automatic control of the material surface treatment system, does not disclose the specific implementation method of complex actions such as angle pulling and dust flashing through the coordinated action of two RGV trolleys when processing inclined hanging parts. Existing technology announcement No. CN107557708B, patent title: "A Closed-Loop Hot-dip Galvanizing Production Line and Control Method," although involving a closed-loop hot-dip galvanizing production line, focuses on iron content control in the pretreatment stage, rather than refined automatic control of the RGV dual-carriage actions during the galvanizing process. Therefore, existing technologies lack a method that can complete high-precision, automated galvanizing operations through the coordinated action of two trolleys for different workpiece types. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a fully automated galvanizing method in the field of material surface treatment technology. By establishing a multi-dimensional galvanizing model and combining dual RGV trolley collaborative control and intelligent zinc ash monitoring, the galvanizing process is fully automated and highly precise.

[0005] To achieve the above objectives, the present invention provides a fully automated galvanizing method in the field of material surface treatment technology, comprising: establishing an automated galvanizing model, the model including process parameters of the material to be galvanized; and performing galvanizing operations above a zinc pot via the coordinated operation of two RGV trolleys; the two RGV trolleys include a walking drive motor, a walking positioning code reader, a lifting drive motor, a lifting positioning encoder, a weight detection sensor, a lifting wire rope, and a lifting hook; the method includes the following steps: S1: The main control system retrieves the corresponding galvanizing process parameters from the automatic galvanizing model according to the type of material to be galvanized; S2: The RGV-A and RGV-B trolleys move the fixture and the material to be plated to the top of the zinc pot and control the door to close. S3: The system collects the zinc bath temperature in real time and determines whether the temperature is within the galvanizing temperature range set in the model. If it is, it issues a prompt that galvanizing is allowed. S4: Start the automatic galvanizing process. The RGV-A end and RGV-B end execute different descent trajectories according to the type of straight or oblique hanging parts. The parts to be galvanized are immersed in the zinc bath at low speed to the set depth. S5: Start zinc immersion timing and perform flash ash operation, which includes up-and-down movement flash ash and left-and-right movement flash ash; S6: Trigger the automatic ash scraping device or issue an ash scraping alarm based on the preset ash scraping reminder time or the zinc ash density monitoring result based on image recognition; S7: After the zinc immersion time is reached, lift the workpiece to be plated according to the preset extraction path, and briefly stop at the height of the zinc scraping head to perform the zinc scraping operation; S8: After scraping off the zinc nodules, proceed to the unloading process.

[0006] Preferably, the automatic galvanizing model includes the following for inclined hangers: RGV-A / RGV-B descending and tilting height, ascending and tilting height, first-down-first-up / first-down-last-up logic, and descending height for scraping the zinc nodule after the zinc liquid is removed.

[0007] Preferably, the descent trajectory described in S4 includes: Direct hanger: Both ends descend at high speed simultaneously to the starting height value for lowering speed, then switch to low-speed immersion in zinc bath; Inclined hanger: The RGV-A or RGV-B end first descends at high speed to form an angle, then both ends descend simultaneously until the workpiece contacts the zinc bath surface, and then switch to low-speed immersion in the zinc bath.

[0008] Preferably, the zinc ash density monitoring results based on image recognition in S6 are obtained in the following way: An image acquisition module is installed above the zinc pot to capture images of the zinc liquid surface in real time. The system analyzes the coverage area of ​​zinc ash in the image. When the coverage area exceeds a preset threshold, it determines that the automatic ash removal trigger condition has been met and controls the automatic ash removal device to perform the ash removal operation.

[0009] Preferably, the automatic ash removal device uses a zinc liquid pump slag discharge assembly or a ash scraper, and the zinc ash is automatically removed by controlling the height adjustment of the slag discharge port or the displacement of the ash scraper.

[0010] Preferably, the flashing operation described in S5 is based on IoT collaborative control logic. The system drives the RGV trolley to perform alternating lifting and walking movements according to the number of up-and-down flashing times and the number of left-and-right flashing times set by the model. The load of the hanger is fed back in real time through the weight detection sensor to prevent the workpiece from bumping into the zinc pot.

[0011] Preferably, when lifting the workpiece to be plated in S7, the system automatically performs a vibration operation according to the process model. The vibration operation is achieved by the micro-amplitude high-frequency operation of the lifting drive motor, which is used to promote the return of zinc liquid and remove residual zinc.

[0012] Preferably, the following control logic is also included: During the unloading process in S8, the system automatically controls the RGV trolley to adjust the unloading speed, time, and angle, and links with the air-cooled or water-cooled equipment for post-plating treatment.

[0013] Preferably, it also includes pause control logic: the system responds to the pause command, pauses the automatic zinc plating process, and automatically triggers safety protection actions when the current or load is abnormal.

[0014] Preferably, the RGV trolley has data barcodes affixed to its running track, and the walking positioning barcode reader achieves accurate positioning by reading the barcodes. The system has a built-in protection window value to prevent the trolley from going out of bounds.

[0015] This invention automates the entire process from material identification and parameter retrieval to zinc immersion, flashing, and extraction, significantly reducing the labor intensity of workers, minimizing direct contact with zinc fumes, and improving the working environment for operators. By precisely controlling parameters such as zinc immersion depth, speed, flashing times, and time, it improves the uniformity and consistency of the zinc coating on the product. By establishing different "zinc immersion models," it can flexibly adapt to the process requirements of workpieces with different shapes, such as straight and angled parts. Detailed Implementation

[0016] The technical solution of the present invention will be further clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. 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. Example 1

[0017] This invention provides a fully automated galvanizing method in the field of material surface treatment technology. An "automatic galvanizing model" is established in the control system. This model includes process parameters corresponding to different small products. The model parameters can be further divided into straight-hanging parts and inclined-hanging parts. The process parameters for straight-hanging parts include: immersion time, galvanizing temperature range, height of the zinc scraper, immersion depth at RGV-A end, immersion depth at RGV-B end, descent speed selection, starting height for descent speed, starting height for ascent speed, number of vertical flashes, distance between vertical flashes, number of horizontal flashes, distance between horizontal flashes, starting time for vertical flashes (based on a percentage of the immersion time or a directly given value), and dust removal reminder time, etc.

[0018] The process parameters for inclined hangers include: all the basic parameters for straight hangers, as well as the descent and tilting heights of RGV-A and RGV-B, the ascending and tilting heights of RGV-A and RGV-B, including the first-down-first-up / first-down-last-up strategy, and the descent height for scraping the zinc nodule and leveling it after the zinc liquid is removed from RGV-A and RGV-B.

[0019] (1) Mode selection and parameter matching: Select the "automatic galvanizing" mode on the computer in the main control room or the galvanizing operation box on the boiler. Before the material enters the galvanizing process, the operator matches and selects the corresponding "galvanizing model" according to the material to be galvanized, and loads the parameters into the "current parameter settings" display area.

[0020] (2) Temperature verification and start-up: After the RGV vehicle transports the material to be plated into the galvanizing area, the gate is closed. The control system compares the temperature parameters set in the model with the real-time galvanizing temperature range of the part to be plated. If the temperature is qualified, it issues a "galvanizing allowed" prompt. When the conditions are met, click "start" to enter the automatic galvanizing process. The system interface displays the immersion time and the current process step in real time.

[0021] (3) Immersion in a zinc bath: Direct-hanging component: The RGV-A and RGV-B ends simultaneously descend rapidly at 2-20 m / min for a certain distance, and then switch to a low speed of 0-2 m / min to immerse the part to be plated into the zinc bath at a low speed until the set zinc immersion depth value is reached.

[0022] For inclined hanging parts: First, perform an angle-drawing operation. The RGV-A or RGV-B end will quickly descend a certain distance according to the set value to form an angle. Then, both ends will descend quickly at the same time until the workpiece contacts the zinc liquid surface. Then, switch to low-speed immersion in the zinc bath; or directly descend quickly until it is about to be fully immersed in the zinc liquid, then switch to low-speed immersion until the set depth is reached.

[0023] (4) Zinc plating timing and flashing operation: After the workpiece is fully immersed in the zinc bath, the zinc plating timing begins. According to the setting, after the upper and lower flashing start time is reached, the RGV-A end and the RGV-B end begin to alternately move up and down, and the cycle number is until the set value is reached. After the left and right flashing start time is reached, the two ends begin to move left and right, and the cycle number is until the set value is reached. At this time, attention should be paid to setting safety limits to avoid the workpiece from bumping into the zinc pot.

[0024] (5) Ash removal reminder: When the ash removal reminder time is up, the galvanizing alarm will sound to remind the operator to start the ash removal operation.

[0025] (6) Extraction and scraping of zinc nodules: Direct-mounted components: After the zinc immersion time is up, according to the lifting speed matched to the process, RGV-A and RGV-B rise simultaneously to the height value of the zinc scraping nodule, pause briefly, control the zinc liquid, and allow the operator to scrape off the zinc nodule in coordination.

[0026] Inclined hanger: Based on the process matching lifting speed, first pull the angle, the RGV-A or RGV-B end rises a certain distance to form an angle, and then rises simultaneously until the lower end leaves the zinc liquid surface, and quickly rises to the height of the zinc scraper and pauses briefly. During the extraction process, the system automatically performs vibration operation to accelerate the zinc liquid reflux and remove residual zinc. According to process requirements, the system can automatically start the cooling fan to blow air while lifting to avoid product color difference.

[0027] (7) Unloading and End: After the zinc scraping operation is completed, the system automatically selects or the operator clicks "Zinc plating complete" to enter the unloading process. The system automatically adjusts the unloading speed, time and angle according to the workpiece requirements to meet the requirements of air cooling or water cooling process. After the zinc immersion time is up, the system automatically stores the zinc immersion time and zinc immersion temperature and displays the ash removal indicator light. After the operator removes the ash, clicks the unloading button to enter the unloading process.

[0028] (8) Intervention and switching: During the process, you can click "Pause" to stop the process step; you can click "Early Extraction" to make the system enter the extraction process in advance; if manual intervention is required, you can switch to "Manual Zinc Plating Mode" at any time and let the controller enter the manual zinc plating process. Example 2

[0029] 1. Establishment of the galvanizing model: The operator selects the "Automatic Galvanizing" mode in the main control room or galvanizing control box, and matches the type of large material to be galvanized. The model parameters are then displayed in the "Current Parameter Settings" area. The parameters in the model include: Zinc immersion depth: RGV-A and B ends are set separately to accommodate workpieces of different sizes.

[0030] Speed ​​strategy: Use high speed (2-20 m / min) to descend to near the liquid surface, then switch to low speed (0-2 m / min) for immersion to prevent splashing.

[0031] Flashing logic: Set the number of flashes vertically to 3 times with a distance of 0.1m and the number of flashes horizontally to 2 times with a distance of 0.05m, and set the start time as a percentage of the zinc immersion time.

[0032] Lifting mode: For inclined hanging parts, set the logic of "first down first up" (A end down first, A end up first) or "first down then up" (A end down first, B end up later), etc.

[0033] 2. Analysis of the automatic galvanizing process: Start-up: The workpiece to be plated enters the galvanizing area, the door is closed, and the system compares the model temperature parameters with the actual zinc bath temperature in real time. If the temperature is qualified, the system will prompt "Galvanizing allowed".

[0034] Immersion: After clicking start, the two RGV vehicles will execute actions according to the model instructions. For straight-mounted parts, both ends will descend simultaneously; for angled parts, one end will descend first to form an angle, and then they will descend synchronously.

[0035] Flashing operation: After the galvanizing timer starts, the system triggers the alternating up and down flashing of RGV-A and B ends according to the set time points. The RGV trolley moves along the track to perform left and right flashing. During the flashing process, the system monitors the load changes in real time through the weight detection sensor to prevent the workpiece from hitting the zinc pot wall.

[0036] Intelligent slag removal: During automatic operation, the image acquisition module continuously acquires images of the zinc bath surface. The system calculates the slag coverage rate, and when this coverage rate exceeds a preset threshold, the system triggers one of two responses: If equipped with an automatic dust removal device, drive the device to perform the dust removal action; If an automatic slag removal device is not installed, the galvanizing alarm will be activated and the slag removal indicator light will be illuminated to prompt the operator to perform manual slag removal.

[0037] Lifting and scraping zinc nodules: After the zinc immersion time is up, the system performs the extraction operation. For inclined hanging parts, the system first straightens the angle and then lifts them to the height for scraping zinc nodules. During the short pause at this height, the system automatically activates the vibration assistance function, using the lifting motor to promote the return of zinc liquid through slight vibration. At the same time, the operator or robotic arm performs the scraping of zinc nodules.

[0038] Unloading process: After scraping off the zinc nodules, click "Zinc plating complete". The system will automatically adjust the unloading speed and angle according to the model and link the air cooling system to prevent color difference of the workpiece.

[0039] 3. Anomaly Handling and Protection: Pause and Extract: The system supports "pause" and "early extraction" functions and has a current / load monitoring and protection mechanism to prevent equipment damage.

[0040] Mode switching: In case of an emergency, the system can be switched to manual mode with one click, and the controller will enter the manual operation process.

[0041] Examples 1 and 2, through the combination of model-driven and intelligent sensing, realize the full-process automation from immersion to unloading, effectively solving the core problems in the existing technology such as reliance on human experience, delayed zinc ash treatment, and easy deformation of inclined hanging parts, and significantly improving the automation level and product quality of the hot-dip galvanizing industry.

[0042] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention is limited to these examples; within the framework of the invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of the different aspects of the invention as described above, which are not provided in detail for the sake of brevity. Any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A fully automated zinc plating method in the field of material surface treatment technology, characterized in that, include: An automated galvanizing model is established, which includes the process parameters of the material to be galvanized. Galvanizing is performed above a zinc pot via the coordinated operation of two RGV trolleys. Each RGV trolley includes a drive motor, a positioning reader, a lifting drive motor, a lifting positioning encoder, a weight sensor, a lifting wire rope, and a lifting hook. The method includes the following steps: S1: The main control system retrieves the corresponding galvanizing process parameters from the automatic galvanizing model according to the type of material to be galvanized; S2: The RGV-A and RGV-B trolleys move the fixture and the material to be plated to the top of the zinc pot and control the door to close. S3: The system collects the zinc bath temperature in real time and determines whether the temperature is within the galvanizing temperature range set in the model. If it is, it issues a prompt that galvanizing is allowed. S4: Start the automatic galvanizing process. The RGV-A end and RGV-B end execute different descent trajectories according to the type of straight or oblique hanging parts. The parts to be galvanized are immersed in the zinc bath at low speed to the set depth. S5: Start zinc immersion timing and perform flash ash operation, which includes up-and-down movement flash ash and left-and-right movement flash ash; S6: Trigger the automatic ash scraping device or issue an ash scraping alarm based on the preset ash scraping reminder time or the zinc ash density monitoring result based on image recognition; S7: After the zinc immersion time is reached, lift the workpiece to be plated according to the preset extraction path, and briefly stop at the height of the zinc scraping head to perform the zinc scraping operation; S8: After scraping off the zinc nodules, proceed to the unloading process.

2. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, The automatic galvanizing model includes the following for inclined hangers: RGV-A / RGV-B descending and tilting height, ascending and tilting height, first-down-first-up / first-down-last-up logic, and the descending height for scraping the zinc nodule after the zinc liquid is removed.

3. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, The descent trajectory described in S4 includes: Direct hanger: Both ends descend at high speed simultaneously to the starting height value for lowering speed, then switch to low-speed immersion in zinc bath; Inclined hanger: The RGV-A or RGV-B end first descends at high speed to form an angle, then both ends descend simultaneously until the workpiece contacts the zinc bath surface, and then switch to low-speed immersion in the zinc bath.

4. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, The zinc ash density monitoring results based on image recognition described in S6 are obtained through the following methods: An image acquisition module is installed above the zinc pot to capture images of the zinc liquid surface in real time. The system analyzes the coverage area of ​​zinc ash in the image. When the coverage area exceeds a preset threshold, it determines that the automatic ash removal trigger condition has been met and controls the automatic ash removal device to perform the ash removal operation.

5. The fully automated zinc plating method in the field of material surface treatment technology according to claim 4, characterized in that, The automatic ash removal device uses a zinc liquid pump slag discharge assembly or a ash scraper, and achieves automatic removal of zinc ash by controlling the height adjustment of the slag discharge port or the displacement of the ash scraper.

6. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, The flashing operation described in S5 is based on IoT collaborative control logic. The system drives the RGV trolley to perform alternating lifting and walking movements according to the number of up-and-down flashing times and left-and-right flashing times set by the model. The load on the hanger is fed back in real time through the weight detection sensor to prevent the workpiece from bumping into the zinc pot.

7. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, When the workpiece to be plated is lifted in S7, the system automatically performs vibration operation according to the process model. The vibration operation is achieved by the micro-amplitude high-frequency operation of the lifting drive motor, which is used to promote the return of zinc liquid and remove residual zinc.

8. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, It also includes the following control logic: During the unloading process in S8, the system automatically controls the RGV trolley to adjust the unloading speed, time, and angle, and links with the air-cooled or water-cooled equipment for post-plating treatment.

9. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, It also includes pause control logic: the system responds to a pause command, suspends the automatic zinc plating process, and automatically triggers safety protection actions when there is an abnormal current or load.

10. The fully automated zinc plating method in the field of material surface treatment technology according to claim 1, characterized in that, The RGV trolley has data barcodes affixed to its running track. The walking positioning barcode reader achieves precise positioning by reading the barcodes. The system has a built-in protection window value to prevent the trolley from going out of bounds.