A device and method for applying a glaze to a ceramic insulator

Abstract

The application discloses a ceramic insulator glazing device and method, and relates to the field of insulator glazing devices.The ceramic insulator glazing device comprises a manipulator, a glaze bin and an image acquisition unit.The manipulator is used for transferring insulators and completing main body glazing.The glaze bin is arranged on one side of the manipulator and is used for containing glaze.The image acquisition unit is used for acquiring insulator surface images and outputting image acquisition data.A separate bypass fixed-point glazing station is arranged, so that when a single missing insulator is detected, the whole batch of workpieces do not need to be re-dipped, and only the defective area is quantitatively coated with glaze, thereby avoiding the problem that the second glazing of qualified products causes the glaze layer to be too thick, reducing adverse defects such as glaze cracking and insulator electric field distortion in the firing stage, unifying the overall glaze layer thickness standard of the insulator, reducing the probability of workpiece rejection, saving glaze raw materials, and reducing the production time caused by rework.

Description

Technical Field

[0001] This invention relates to the field of insulator glazing devices, specifically to a ceramic insulator glazing device and method. Background Technology

[0002] The insulator glazing device is a specialized piece of equipment for the production of electrical porcelain. It is used to uniformly coat the porcelain insulator blank with a protective glaze layer. It is divided into three types: glazing dipping, glazing spraying, and rotary glazing. It consists of a glaze slurry storage tank, a conveying and clamping mechanism, spraying and glazing actuators, a circulation and recycling system, and an electrical control module. The equipment can clamp various types of insulators, including disc, post, and suspension insulators. It completes the full coverage glazing of the skirts and porcelain body through rotation, lifting, and positioning. It is equipped with a glaze return and filtration structure and is suitable for continuous electrical porcelain processing production lines.

[0003] This type of equipment is highly automated and can replace manual glazing, significantly reducing manpower input. It can precisely control the thickness of the glaze layer, and the finished glaze surface is uniform without defects such as dripping or glaze leakage, improving the insulation and weather resistance of insulators. The glaze slurry can be recycled to reduce raw material loss. Multi-station synchronous operation can increase production capacity. The parameters can be adjusted to adapt to various product specifications. The closed operation reduces dust pollution. The stable and uniform glaze layer also reduces the scrap rate in subsequent firing, resulting in lower overall production costs.

[0004] However, the following shortcomings still exist in the current glazing process: 1. Individual workpiece defects cannot be repaired with glaze independently. Re-immersion of the entire batch exacerbates the uneven glaze thickness. At present, multiple robotic arms simultaneously clamp the glazing production line. If a single insulator has a local defect of missing blank or missing glaze, the entire batch of workpieces can only be re-immersed and glazed. After the qualified products are glazed for the second time, the glaze layer is too thick, which is more likely to cause glaze cracking and electric field distortion problems in the later stage.

[0005] 2. The glaze flow rate cannot match the defect area, and the accuracy of manual glazing is unstable. Traditional offline glazing equipment adopts a constant flow glazing mode, which cannot adaptively adjust the glaze flow rate according to the actual area of ​​the glaze leakage area. Excessive glazing for small defects will cause glaze nodules, while insufficient glazing for large defects will result in glazing failure. Manual control relies on experience, and the consistency of glazing cannot be guaranteed.

[0006] 3. The glaze that is poured back into the glaze container easily carries air bubbles. Without a targeted defoaming structure, it affects subsequent glazing. The glaze that is poured back into the glaze container during conventional glazing replenishment operations will contain a large number of air bubbles and will flow back directly into the glaze container.

[0007] To address the shortcomings of existing technologies, this invention provides a ceramic insulator glazing device and method to solve the aforementioned problems. Summary of the Invention

[0008] To address the shortcomings of existing technologies, this invention provides a ceramic insulator glazing device and method, which solves the problem that individual insulators in a batch may be glazed and it is inconvenient to individually repair them.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a ceramic insulator glazing device, comprising: A robotic arm is used to transfer insulators and complete the glazing process on the main body. A glaze container, located on one side of the robotic arm, is used to hold glaze. The image acquisition unit is used to acquire images of the insulator surface and output image acquisition data. The drive unit is connected to the discharge end of the glaze hopper and is used to extract glaze and transport it in sections. An integrated processing unit is connected to the image acquisition unit and the driving unit respectively. It is used to receive image acquisition data transmitted by the image acquisition unit, process the acquisition data, and output control commands to control the start and stop of the driving unit. The drive unit includes a feed pipe, a drive pump, a flow divider, and a solenoid valve; The integrated processing unit analyzes the image data of the insulator's outer wall acquired by the image acquisition unit, and then activates the corresponding solenoid valve based on the defect information. This allows for targeted flow regulation, enabling the glaze in the glaze tank to be applied to the defective area of ​​the insulator, thus completing the glaze repair process.

[0010] Preferably, the distribution pipe is installed at the output end of the glaze silo to guide the glaze into the drive pump installed at its end. The output end of the drive pump is equipped with a diversion pipe, and the output adjustment end of each diversion pipe is equipped with a solenoid valve for switching the pipeline on and off. The drive pump is installed on the side wall of the glaze silo via a mounting plate. An electric push rod is installed on the outer wall of the glaze chamber. The output end of the electric push rod is connected to a linear motor for adjusting the glaze application position via a connecting sleeve. The sliding end of the linear motor is connected to the glaze application chamber. The glaze application chamber is divided into multiple independent chambers, and its output end corresponds to the upper end of the glaze chamber.

[0011] Preferably, the image acquisition unit includes an industrial camera installed on the outer wall of the material hopper, the output end of the industrial camera corresponds to the robotic arm, and multiple industrial cameras are signal-connected to the integrated processing unit.

[0012] Preferably, the integrated processing unit includes an integrated processor and an edge gateway installed on the upper surface of the material hopper, wherein the integrated processor is used to receive image information from an industrial camera to start the drive pump.

[0013] Preferably, the edge gateway is connected to an external cloud signal to transmit image information captured by the industrial camera to the cloud and compare it with insulator image data in the cloud database; The comparison results are then sent to the integrated processor, which provides early warnings.

[0014] Preferably, a slide is installed on the upper end face of the glaze bin, and an anti-foaming scraper is slidably sleeved on the inner wall of the slide. A sealing plate for sealing the output end of the glaze bin is installed on the outer wall of the linear motor. The robotic arm, linear motor, electric actuator, and drive pump are all connected to the integrated processor via signal transmission.

[0015] Preferably, a hydraulic push rod is installed on the upper end face of the slide, and the output end of the hydraulic push rod is installed on the upper end face of the defoaming scraper.

[0016] This invention also discloses a method for applying a glazing device to a ceramic insulator, applicable to the aforementioned ceramic insulator glazing device, the method comprising the following steps: S1, image acquisition, recognition and positioning, robotic arm transports insulator to workstation, industrial camera acquires image of ceramic surface and transmits to integrated processor, system extracts glaze leakage contour, calculates defect area, locks defect coordinates, and outputs basic parameters required for calculation; S2, flow parameter calculation output, the integrated processor substitutes the flow formula to calculate the target glazing flow, converts the solenoid valve opening, matches the corresponding branch valves of the defect, and synchronously sends start / stop and opening adjustment control signals to the drive pump and solenoid valve. S3, multi-axis positioning aligns with the defective area, electric push rod and linear motor drive the glazing bin to move, completing the glazing positioning; S4, quantitative and fixed-point glazing and resetting, the drive pump draws glaze and transports it through pipeline, and the corresponding solenoid valve applies glaze quantitatively according to the set opening degree; after the glazing is completed, the pump and valve are shut off, all moving mechanisms are reset, and it waits for the next insulator processing and inspection.

[0017] Preferably, the system extracts the glaze leakage contour, calculates the defect area, locks the defect coordinates, and outputs the formula for the basic parameters required for the calculation as follows: ; The real-time output volumetric flow rate of the glazing process is measured in m³ / s. The final glaze output flow rate at the outlet of the solenoid valve is used by the integrated processor to output control signals based on this value to adjust the frequency of the drive pump and the opening of the solenoid valve. Minimum glaze replenishment flow rate, in m³ / s. This is the minimum flow rate maintained by the pipe when a tiny defect in the blank is detected, ensuring that the pipe is not blocked and the glaze flows out continuously. : glaze replenishment flow rate coefficient per unit area, in m / s, is an equipment calibration constant determined experimentally by the solid content and viscosity of the glaze slurry, the diameter of the glaze spray nozzle, and the diameter of the delivery pipeline; the thicker the glaze slurry and the smaller the nozzle, the smaller the value of k. : The actual area of ​​the exposed glaze leakage area of ​​the insulator obtained by the industrial camera, in square meters. The real defect area is calculated by the integrated processing unit after grayscale threshold segmentation and contour extraction of the camera image, and is the input variable of the formula. Position correction factor, dimensionless 0-1, compensates for differences in glaze adhesion efficiency at different locations of the insulator: inner side of the shed / outer wall of the flange / ball head. Cavity dead angle <1, take a flat outer surface =1.

[0018] Preferably, the flow rate parameter calculation output, when substituted into the flow rate formula by the integrated processor, yields the following flow rate formula for calculating the target glazing flow rate: ; : The real-time flow opening area of ​​the solenoid valve, in square meters; the controller output signal corresponds to the opening area of ​​the solenoid valve. : Maximum flow cross-sectional area of ​​the solenoid valve when fully open, in square meters; inherent structural parameter of the valve, a fixed constant. The maximum allowable design flow rate of the entire glazing pipeline is in m³ / s. The rated output upper limit flow rate of the drive pump is the factory calibration value of the equipment. The calculation steps are as follows: The industrial camera captures images of the insulator surface and transmits them to an integrated processor, which uses a built-in algorithm to calculate the true area of ​​the missing blank region. Simultaneously identify the location of the defect and output a correction coefficient. ; Substitute into the main flow formula Calculate the target output flow ; Using the opening conversion formula Will Convert to target opening area of ​​solenoid valve ; The integrated processor outputs electrical signals to synchronously adjust the output power of the corresponding branch drive pump and match the opening degree of the solenoid valve. Only the solenoid valve of the branch pipe corresponding to the defect is opened, while the other branches remain closed, realizing point-to-point and quantitative adaptive glazing repair.

[0019] The technical effects and advantages of this invention are as follows: 1. This ceramic insulator glazing device, by setting up an independent bypass fixed-point glazing station, eliminates the need to re-soak the entire batch of workpieces when a single defective blank insulator is detected. Instead, it applies a quantitative amount of glaze to the defective area, avoiding the problem of excessively thick glaze layers caused by secondary glazing of qualified products. This reduces defects such as glaze cracking and insulation electric field distortion during the firing stage, lowers the probability of workpiece scrap, saves glaze raw materials, and reduces production time caused by rework.

[0020] 2. This device, by setting up an integrated processing unit, calculates and matches the glazing flow rate based on the glaze leakage area measured by the industrial camera, and links the bidirectional drive pump and the corresponding branch solenoid valve to adjust the opening in real time, so as to achieve adaptive quantitative glaze replenishment. For small glaze leakage areas, the flow rate is automatically reduced to prevent glaze accumulation, while for large defects, the flow rate is increased to ensure complete repair coating. It unifies the glaze repair process standards and improves the consistency of repair coating.

[0021] 3. This device is equipped with a bidirectional pump to recover all residual glaze in the pipeline and work station after glazing, and return it to the glaze silo. The defoaming scraper is driven by a hydraulic push rod to slide back and forth along the surface of the glaze liquid to scrape off the surface bubbles carried by the returned glaze, preventing bubbles from flowing into the main glazing process with the glaze, eliminating pinhole defects on the surface of the insulator, and providing a good glaze liquid environment for subsequent insulator application. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the robotic arm in this invention; Figure 3 This is a schematic diagram of the glaze container in this invention; Figure 4 This is a schematic diagram of the driving pump in this invention; Figure 5 This is a schematic diagram of the material hopper structure in this invention; Figure 6 for Figure 2 Schematic diagram of the structure at point A; Figure 7 This is a schematic diagram of the operation process of the present invention; Figure 8 This is a classification diagram of the various units in this invention; Figure 9 This is a schematic diagram of the glazing steps for the insulator in this invention.

[0024] In the picture: 1. Robotic arm; 2. Image acquisition unit; 201. Industrial camera; 3. Drive unit; 301. Feed distribution pipe; 302. Drive pump; 303. Diverter pipe; 304. Solenoid valve; 4. Integrated processing unit; 401. Integrated processor; 402. Edge gateway; 5. Glaze bin; 6. Electric push rod; 7. Linear motor; 8. Sprinkler bin; 9. Slide seat; 10. Defoaming scraper; 11. Sealing plate; 12. Hydraulic push rod. Detailed Implementation

[0025] 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.

[0026] This embodiment discloses a ceramic insulator glazing device, according to the attached... Figure 1 To be continued Figure 9 As shown, it includes: Robot 1 is used to transfer insulators and complete the main body glazing operation. It connects to the front-end conveying equipment to clamp and limit multiple insulators, thereby moving them to the glazing area for the glazing process. The glaze container 5 is located on one side of the robot arm 1 and is used to hold glaze. The glaze liquid can be stored in the glaze container 5 to ensure that the insulator can be stably glazed during immersion. At the same time, the large volume of storage can prevent the glaze from drying out. Image acquisition unit 2 is used to acquire images of the insulator surface and output image acquisition data. It can acquire images of the complete outer wall of the insulator from all directions, simultaneously complete image digitization conversion, and transmit standardized image acquisition data to integrated processing unit 4 in real time to provide raw image materials for defect identification and area calculation. Drive unit 3 is connected to the discharge end of glaze bin 5 and is used to extract glaze and transport it in sections. Drive unit 3 is connected to the discharge end of glaze bin 5 through pipeline and has multiple independent conveying branches built in. It relies on bidirectional drive pump 302 to extract glaze in the bin and cooperates with solenoid valves 304 of each branch to realize the on / off of sections and flow regulation. It can deliver glaze to the defective area of ​​insulator separately. The integrated processing unit 4 is connected to the image acquisition unit 2 and the driving unit 3 respectively. It is used to receive image acquisition data transmitted by the image acquisition unit 2, process the acquisition data, and output control commands to control the start and stop of the driving unit 3. The integrated processing unit 4 establishes communication signal connections with the image acquisition unit 2 and the driving unit 3 respectively, and can receive insulator surface image data in real time. It can complete the location of glaze leakage defects and the calculation of exposed area through the built-in algorithm, and calculate the matching output flow by substituting it into the flow model. The integrated processing unit 4 generates multiple independent control commands based on the calculation results, which respectively regulate the operating power of the bidirectional drive pump 302 and the opening degree of the corresponding branch solenoid valve 304, and precisely control the start and stop of the drive unit 3 and the output glaze flow rate to achieve fixed-point and quantitative automatic glaze replenishment. The drive unit 3 includes a feed pipe 301, a drive pump 302, a flow divider 303, and a solenoid valve 304; The integrated processing unit 4 analyzes the image data of the insulator's outer wall acquired by the image acquisition unit 2, and then activates the corresponding solenoid valve 304 based on the defect information. This allows the glaze in the glaze tank 5 to be applied to the defect in the insulator through targeted flow regulation, thus completing the glaze repair process.

[0027] The feed pipe 301 is installed at the output end of the glaze bin 5 to guide the glaze into the drive pump 302 installed at its end. The output end of the drive pump 302 is equipped with a diversion pipe 303. Each diversion pipe 303 is equipped with a solenoid valve 304 for switching the pipeline on and off. The drive pump 302 is installed on the side wall of the glaze bin 5 through a mounting plate. The glaze from the glaze bin 5 can be received through the distribution pipe 301. After receiving the start signal, the drive pump 302 can quickly draw the glaze and deliver it to the back end to replenish the glaze on the insulator. The bidirectional suction drive pump 302 can meet the requirements of glaze suction and return, and avoid the accumulation of glaze with a certain viscosity in the distribution pipe 301 and the diversion pipe 303. By setting the solenoid valve 304, the flow rate of the glaze can be controlled by following the signal drive of the integrated processing unit 4, so as to avoid the phenomenon of small defects and large flow, which would lead to repeated glazing and affect the glazing quality of the insulator. An electric push rod 6 is installed on the outer wall of the glaze tank 5. The output end of the electric push rod 6 is connected to a linear motor 7 for adjusting the glaze pouring position via a connecting sleeve. The sliding end of the linear motor 7 is connected to the glaze pouring tank 8. The glaze pouring tank 8 is divided into multiple independent chambers, and its output end corresponds to the upper end of the glaze tank 5. By setting the electric push rod 6, the stroke movement of the output end of the electric push rod 6 can drive the linear motor 7 and the glazing bin 8 to adjust the height during liquid replenishment. The preset height can avoid blocking the angle adjustment of the insulator during normal glazing. By using the linear motor 7, the position of the glazing bin 8 can be adjusted. When the industrial camera 201 detects a defect, the position of the glazing bin 8 can be adjusted. When there is no defect, it can be moved back to reduce the impact on space and maintain the stability of the robot arm 1 when it glazes the insulator. With the built-in multiple chambers of the glaze chamber 8, the glaze will not be mixed in the glaze chamber 8 after the drive pump 302 draws it in. The glaze can be drawn into the glaze chamber 8 by the activation of the corresponding solenoid valve 304, and then the glaze can be poured onto the outer wall of the insulator through the corresponding outlet. By separating the inner cavity, it is possible to prevent the oil from being discharged from another output end during the glazing process, which would cause non-defective insulators to be replenished with glaze. Furthermore, by setting the output end to correspond with the insulator, the glaze can be applied to the outer surface of the insulator immediately.

[0028] The image acquisition unit 2 includes an industrial camera 201 installed on the outer wall of the material hopper 8. The output end of the industrial camera 201 corresponds to the robot arm 1. Multiple industrial cameras 201 are connected to the integrated processing unit 4. The integrated processing unit 4 includes an integrated processor 401 and an edge gateway 402 installed on the upper surface of the material hopper 8. The integrated processor 401 is used to receive the image information from the industrial camera 201 and start the drive pump 302. Multiple industrial cameras 201 are uniformly mounted on the outer wall of the glazing bin 8, with their lenses facing the insulators delivered by the robotic arm 1. All cameras establish a signal transmission link with the integrated processing unit 4. The integrated processing unit 4 is composed of an integrated processor 401 and an edge gateway 402, which are arranged together on the top of the glazing bin 8. The processor can read the surface image information transmitted back by the camera, complete the defect judgment, and output a signal to control the drive pump 302 to start and perform glazing repair.

[0029] Edge gateway 402 connects to external cloud signals to transmit image information captured by industrial camera 201 to the cloud and compare it with insulator image data in cloud database; The comparison results are then sent to the integrated processor 401 for early warning. The edge gateway 402 can establish a remote communication link with an external cloud server, and synchronously upload the appearance images of ceramic parts captured by the industrial camera 201 to the cloud system. The cloud retrieves the built-in standard insulator image library to complete the image comparison and analysis, and then sends the defect judgment feedback data back to the integrated processor 401. The equipment automatically triggers an early warning based on the returned information, reminding the staff to handle abnormal workpieces.

[0030] A slide block 9 is installed on the upper end face of the glaze bin 5. A defoaming scraper 10 is slidably sleeved on the inner wall of the slide block 9. A sealing plate 11 for sealing the output end of the glaze bin 8 is installed on the outer wall of the linear motor 7. The robotic arm 1, linear motor 7, electric push rod 6, and drive pump 302 are all connected to the integrated processor 401 via signal. A hydraulic push rod 12 is installed on the upper end face of the slide 9, and the output end of the hydraulic push rod 12 is installed on the upper end face of the defoaming scraper 10. The slide block 9 mounted on the top surface of the glaze tank 5 can keep the sliding limit of the defoaming scraper 10. The slide block 9 is equipped with a hydraulic push rod 12, which can drive the defoaming scraper 10 to slide back and forth to complete the defoaming of the liquid surface after the insulator is replenished with glaze. The sealing plate 11 set on the outside of the linear motor 7 can be squeezed and deformed by the rubber sealing plate 11 after the insulator is finished and reset by the glaze tank 8, thereby sealing the output end of the glaze tank 8 and preventing residual glaze from dripping. The robotic arm 1, linear motor 7, hydraulic push rod 12 and drive pump 302 are all connected to the integrated processor 401. The processor coordinates the synchronous action of each component to enhance the uniformity of equipment operation. It should be noted that the drive components designed in this article are all self-powered and support linkage functions. Since this is already existing technology, it will not be described in detail in this article.

[0031] Example 1, in conjunction with Appendix Figure 1 To be continued Figure 9 The complete workflow is explained in detail below, with the following steps: S1, Image acquisition, recognition and positioning, Robot 1 transports insulator to workstation, Industrial camera 201 acquires image of ceramic surface and transmits to integrated processor 401, System extracts glaze leakage contour, calculates defect area, locks defect coordinates, and outputs basic parameters required for calculation. After the robotic arm 1 smoothly moves the insulator to be inspected to the glazing work station, multiple sets of industrial cameras 201 simultaneously capture images of the complete surface of the ceramic part from multiple angles and transmit the image signals to the integrated processor 401 in real time. The built-in recognition algorithm of the equipment automatically analyzes the image, accurately outlines the contour of the local glazing leakage area, calculates the actual coverage area of ​​the defect, and simultaneously locates the coordinate position of the defect, generating all the calculation parameters required for subsequent flow adjustment. S2, flow parameter calculation output, integrated processor 401 substitutes the flow formula to calculate the target glazing flow, converts the opening of solenoid valve 304, matches the corresponding branch valve of the defect, and synchronously sends start / stop and opening adjustment control signals to drive pump 302 and solenoid valve 304. The integrated processor 401 retrieves the defect area data obtained from the previous identification, substitutes it into the preset flow calculation model to obtain the standard value of glazing flow rate adapted to the defect, and then calculates the opening range of the corresponding solenoid valve 304. The system automatically matches the conveying branch valve body corresponding to the defect location and synchronously sends control signals to the bidirectional drive pump 302 and the selected solenoid valve 304 to uniformly regulate the pump body operation status and valve opening degree, and accurately match the glazing repair needs. S3, multi-axis positioning aligns with the defective area, electric push rod 6, in conjunction with linear motor 7, drives the glazing bin 8 to move, completing the glazing positioning; After receiving the positioning command from the processor, the electric push rod 6 and the linear motor 7 cooperate to form a multi-axis linkage structure, which together drive the entire coating bin 8 to move and adjust. The position of the discharge port of the coating bin 8 is calibrated by the coordinated displacement of the two components, so that it is aligned with the insulator in the defect area on the surface, and the alignment process before the coating is completed is completed, and the coating operation is carried out while waiting for the glaze to be delivered. S4, quantitative and fixed-point glazing and reset, drive pump 302 to draw glaze and transport it through pipeline, corresponding solenoid valve 304 to apply glaze quantitatively according to the set opening; after the glazing is completed, the pump and valve are shut off, all moving mechanisms are reset, and wait for the next insulator processing and inspection. The integrated processor 401 outputs a control signal to start the drive pump 302, which draws glaze from the glaze tank 5 and transports it along the pipeline to the designated branch. The solenoid valve 304, which matches the defect location, releases glaze according to the calculated opening degree, and accurately completes the fixed-point and quantitative glaze replenishment. After the touch-up coating is completed, the system automatically switches the operating status of the pump body and the solenoid valve 304, and draws the glaze in the coating bin 8 and the diversion pipe 303 back into the glaze bin 5. After completion, the linear motor 7 and the electric push rod 6 drive the coating bin 8 back to the initial position, and the whole machine enters the standby mode. At the same time, the hydraulic push rod 12 is activated to drive the defoaming scraper 10 to defoam the glaze liquid surface on the surface of the glaze bin 5, so as to avoid the bubbles affecting the subsequent glazing of the insulator. When the glazing bin 8 is reset, its output end will be squeezed by the sealing plate 11, thereby sealing its output end, waiting for the next insulator to be sent into the work station for cyclic processing. The system extracts the glaze leakage contour, calculates the defect area, locks the defect coordinates, and outputs the formulas for the basic parameters required for the calculation: ; The real-time output volumetric flow rate of the glaze is measured in m³ / s. The final glaze output flow rate at the outlet of the solenoid valve 304 is used by the integrated processor 401 to output control signals based on this value to adjust the frequency conversion frequency of the drive pump 302 and the opening degree of the solenoid valve 304. Minimum glaze replenishment flow rate, in m³ / s. This is the minimum flow rate maintained by the pipe when a tiny defect in the blank is detected, ensuring that the pipe is not blocked and the glaze flows out continuously. : glaze replenishment flow rate coefficient per unit area, in m / s, is an equipment calibration constant determined experimentally by the solid content and viscosity of the glaze slurry, the diameter of the glaze spray nozzle, and the diameter of the delivery pipeline; the thicker the glaze slurry and the smaller the nozzle, the smaller the value of k. The actual area of ​​the exposed glaze leakage area of ​​the insulator identified by the industrial camera 201 is in square meters. The actual defect area is calculated by the integrated processing unit 4 after grayscale threshold segmentation and contour extraction of the camera image. This area is the input variable for the formula. Position correction coefficient, dimensionless (0-1), compensates for differences in glaze adhesion efficiency at different locations of the insulator: inner side of the shed / outer wall of the flange / ball head. Cavity dead angle <1, take a flat outer surface =1; The flow rate parameter is calculated and output. Substituting this into the flow rate formula using the integrated processor 401, the target glazing flow rate is calculated as follows: ; The real-time flow opening area of ​​solenoid valve 304 is expressed in square meters. The controller output signal corresponds to the opening area of ​​solenoid valve 304. : The maximum flow cross-sectional area of ​​the 304 solenoid valve when fully open, in square meters. This is an inherent structural parameter of the valve and a fixed constant. The maximum allowable design flow rate of the entire glazing pipeline is in m³ / s. The rated output upper limit flow rate of the drive pump 302 is the factory calibration value of the equipment. The calculation steps are as follows: Industrial camera 201 captures images of the insulator surface and transmits them to integrated processor 401. Integrated processor 401 uses a built-in algorithm to calculate the true area of ​​the missing blank region. Simultaneously identify the location of the defect and output a correction coefficient. ; Substitute into the main flow formula Calculate the target output flow ; Using the opening conversion formula Will Convert to target opening area of ​​solenoid valve 304 ; The integrated processor 401 outputs an electrical signal to synchronously adjust the output power of the corresponding branch drive pump 302 and match the opening degree of the solenoid valve 304. Only the solenoid valve 304 of the branch corresponding to the defect is opened, while the other branches remain closed, achieving point-to-point and quantitative adaptive glazing repair.

[0032] Example 2, this example takes the normal glazing of insulators as an example: After the equipment is started, the robotic arm 1 clamps the insulator to be processed and moves it to the glazing area next to the glaze bin 5. The ceramic part is immersed in the glaze liquid in the bin to complete the basic glazing operation in the whole area. The glazing bin 8 is driven by the electric push rod 6 and the linear motor 7 to retract to the avoidance position. The external industrial camera 201 simultaneously collects the complete image of the ceramic part and uploads it to the integrated processor 401. The processor calls a pre-trained recognition algorithm to analyze the image. After edge segmentation and pixel conversion, it is determined that the glaze layer on the outer wall of the insulator is intact and there are no defects such as glaze leakage or exposed blank. The edge gateway 402 simultaneously uploads the image to the cloud for comparison with standard samples. If there are no abnormalities, the warning and glaze replenishment process will not be triggered. The system does not require starting the drive pump 302 and each branch solenoid valve 304. The hydraulic push rod 12 drives the defoaming scraper 10 to slide back and forth continuously, cleaning the floating bubbles on the surface of the glaze tank 5 and purifying the glaze liquid. All mechanisms remain in standby mode. The robotic arm 1 transfers the processed insulators out of the machine and simultaneously clamps the next blank to enter the glazing process for cyclic operation.

[0033] Example 3: This example uses the entire process of glaze application as an example. After the equipment is started, the robotic arm 1 clamps the insulator and transfers it to the glazing station. The entire glazing operation is completed on one side of the glaze bin 5. Then, multiple sets of industrial cameras 201 on the outside of the glazing bin 8 simultaneously take pictures of the complete outer wall of the insulator from multiple angles. The collected images are digitally transmitted in real time to the integrated processor 401 on the top of the glazing bin 8. At the same time, the edge gateway 402 uploads the images to the cloud and compares and verifies them with the standard insulator image library in the cloud. The comparison data is sent back to the processor to complete the second review of defects. If the defects exceed the standard, an early warning is triggered immediately. The processor uses built-in algorithms to outline the glaze leakage, calculate the defect area and lock the precise coordinates, and input the flow model to calculate the appropriate glaze flow. That is, the integrated processor 401 calls the local pre-trained insulator appearance recognition algorithm model, performs grayscale noise reduction and edge threshold segmentation on the high-definition surface image transmitted back by the industrial camera 201, accurately separates the boundary between the ceramic substrate and the exposed glaze leakage area, and completely outlines the contours of various defects. Then, the actual coverage area of ​​the defect is calculated by pixel calibration conversion formula, and the three-dimensional coordinates of the defect are locked by combining the spatial position parameters of the insulator. The processor imports the area and distance parameters into the preset glaze flow fitting model, outputs the standard material supply flow value matching the size of the defect, and then calculates the target opening degree of the corresponding branch solenoid valve 304 by combining the pipeline pressure drop characteristics. A precise and controllable valve body adjustment command is generated, and the opening degree of each branch solenoid valve 304 is calculated. The processor issues a command, and the electric push rod 6 and the linear motor 7 are linked to adjust the position of the glaze chamber 8 so that the outlet of the chamber is aligned with the defect area. The bidirectional drive pump 302 draws glaze, and the corresponding solenoid valve 304 opens according to the set opening degree. The partitioned chamber independently delivers glaze for fixed-point glazing. After the glazing is completed, the system shuts down the pump body and solenoid valve 304. The electric push rod 6 and linear motor 7 drive the glazing bin 8 to reset. The sealing plate 11 seals the outlet to prevent glaze from dripping. The bidirectional pump reverses the suction of residual material from the pipeline back to the glaze bin 5. The hydraulic push rod 12 on the top of the bin drives the defoaming scraper 10 to slide back and forth along the slide block 9 to scrape off the surface bubbles of the returned glaze, thus completing the glaze purification. The entire mechanism returns to its standby position. The robotic arm 1 transfers the next insulator, and the entire process of glazing, image detection, quantitative and fixed-point glazing, and glaze defoaming is carried out in a cycle.

[0034] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A ceramic insulator glazing device, characterized in that, include: The robotic arm (1) is used to transfer insulators and complete the glazing operation of the main body; A glaze container (5) is located on one side of the robotic arm (1) and is used to hold glaze. Image acquisition unit (2) is used to acquire images of the insulator surface and output image acquisition data; The drive unit (3) is connected to the discharge end of the glaze bin (5) and is used to extract glaze and transport it in sections. The integrated processing unit (4) is connected to the image acquisition unit (2) and the driving unit (3) respectively. It is used to receive the image acquisition data transmitted by the image acquisition unit (2), process the acquisition data and output control commands to control the start and stop of the driving unit (3). The drive unit (3) includes a feed pipe (301), a drive pump (302), a flow divider (303), and a solenoid valve (304). The integrated processing unit (4) analyzes the image data of the outer wall of the insulator acquired by the image acquisition unit (2), and then activates the corresponding solenoid valve (304) according to the defect information. In this way, the glaze in the glaze tank (5) is applied to the defect of the insulator through targeted flow regulation, thus completing the glaze repair process.

2. The ceramic insulator glazing device according to claim 1, characterized in that, The distribution pipe (301) is installed at the output end of the glaze bin (5) to guide the glaze into the drive pump (302) installed at its end. The output end of the drive pump (302) is equipped with a diversion pipe (303). The output adjustment end of each diversion pipe (303) is equipped with a solenoid valve (304) for switching the pipeline on and off. The drive pump (302) is installed on the side wall of the glaze bin (5) through a mounting plate. An electric push rod (6) is installed on the outer wall of the glaze tank (5). The output end of the electric push rod (6) is connected to a linear motor (7) for adjusting the glaze application position via a connecting sleeve. The sliding end of the linear motor (7) is connected to a glaze application tank (8). The glaze application tank (8) is divided into multiple independent chambers, and its output end corresponds to the upper end of the glaze tank (5).

3. A ceramic insulator glazing device according to claim 2, characterized in that, The image acquisition unit (2) includes an industrial camera (201) installed on the outer wall of the material hopper (8). The output end of the industrial camera (201) corresponds to the robot arm (1). Multiple industrial cameras (201) are connected to the integrated processing unit (4) via signals.

4. A ceramic insulator glazing device according to claim 2, characterized in that, The integrated processing unit (4) includes an integrated processor (401) and an edge gateway (402) installed on the upper surface of the material hopper (8). The integrated processor (401) is used to receive image information from the industrial camera (201) to start the drive pump (302).

5. A ceramic insulator glazing device according to claim 4, characterized in that, The edge gateway (402) is connected to an external cloud signal to transmit image information collected by the industrial camera (201) to the cloud and compare it with insulator image data in the cloud database; The comparison results are then sent to the integrated processor (401) for early warning.

6. A ceramic insulator glazing device according to claim 4, characterized in that, A slide (9) is installed on the upper end face of the glaze bin (5), and a defoaming scraper (10) is slidably sleeved on the inner wall of the slide (9). A sealing plate (11) for sealing the output end of the glaze bin (8) is installed on the outer wall of the linear motor (7). The robotic arm (1), linear motor (7), electric push rod (6), and drive pump (302) are all connected to the integrated processor (401) via signal.

7. A ceramic insulator glazing device according to claim 6, characterized in that, A hydraulic push rod (12) is installed on the upper end face of the slide (9), and the output end of the hydraulic push rod (12) is installed on the upper end face of the defoaming scraper (10).

8. A method for applying a glazing device to a ceramic insulator, applicable to a glazing device for a ceramic insulator as described in any one of claims 1-7, characterized in that, The method includes the following steps: S1, Image acquisition, recognition and positioning, robotic arm (1) transports insulator to workstation, industrial camera (201) acquires ceramic surface image and transmits to integrated processor (401), system extracts glaze leakage contour, calculates defect area, locks defect coordinates, and outputs basic parameters required for calculation; S2, flow parameter calculation output, integrated processor (401) substitutes into the flow formula to calculate the target glazing flow, converts the opening of the solenoid valve (304), matches the corresponding branch valve of the defect, and synchronously sends start / stop and opening adjustment control signals to the drive pump (302) and solenoid valve (304). S3, the multi-axis positioning is aligned with the defect area, and the electric push rod (6) and the linear motor (7) drive the glazing bin (8) to move, completing the glazing positioning. S4, quantitative and fixed-point glazing is applied and reset, the pump (302) is driven to draw glaze and transport it through the pipeline, and the corresponding solenoid valve (304) applies glaze quantitatively according to the set opening degree; after the glazing is completed, the pump and valve are shut down, all moving mechanisms are reset, and the process is waiting for the next insulator processing and testing.

9. A method for applying glaze to a ceramic insulator according to claim 8, characterized in that, The system extracts the glaze leakage contour, calculates the defect area, locks the defect coordinates, and outputs the formula for the basic parameters required for the calculation: ； The real-time output volumetric flow rate of the glaze is in m³ / s. The final glaze output flow rate at the outlet of the solenoid valve (304) is adjusted by the integrated processor (401) according to the value. The frequency of the drive pump (302) and the opening of the solenoid valve (304) are adjusted. Minimum glaze replenishment flow rate, in m³ / s. When a tiny defect in the blank is detected, the minimum flow rate is maintained to ensure that the pipeline is not blocked and the glaze flows out continuously. : glaze replenishment flow rate coefficient per unit area, in m / s, is an equipment calibration constant determined experimentally by the solid content and viscosity of the glaze slurry, the diameter of the glaze spray nozzle, and the diameter of the delivery pipeline; the thicker the glaze slurry and the smaller the nozzle, the smaller the value of k. The actual area of ​​the exposed glaze area of ​​the insulator identified by the industrial camera (201) is in square meters. The real defect area is calculated by the integrated processing unit (4) after grayscale threshold segmentation and contour extraction of the camera image. This area is the input variable of the formula. Position correction factor, dimensionless (0-1), compensates for differences in glaze adhesion efficiency at different parts of the insulator (inner side of the skirt / outer wall of the flange / ball head). Cavity dead angle <1, take a flat outer surface =1.

10. A method for applying glaze to a ceramic insulator according to claim 9, characterized in that, The flow rate parameter is calculated and output. The integrated processor (401) substitutes the output into the flow rate formula to calculate the flow rate in the target glazing flow rate. The flow rate formula is as follows: ； The real-time flow opening area of ​​the solenoid valve (304) is in square meters, and the controller output signal corresponds to the opening area of ​​the solenoid valve (304). : Maximum flow cross-sectional area of ​​the solenoid valve (304) when fully open, in square meters; inherent structural parameters of the valve, fixed constants; The maximum allowable design flow rate of the entire glazing pipeline is in m³ / s. The rated output upper limit flow rate of the drive pump (302) is the factory calibration value of the equipment. The calculation steps are as follows: The industrial camera (201) acquires images of the insulator surface and transmits them to the integrated processor (401). The integrated processor (401) uses a built-in algorithm to calculate the true area of ​​the missing blank region. Simultaneously identify the location of the defect and output a correction coefficient. ; Substitute into the main flow formula Calculate the target output flow ; Using the opening conversion formula Will Convert to target opening area of ​​solenoid valve (304) ; The integrated processor (401) outputs an electrical signal to synchronously adjust the output power of the corresponding branch drive pump (302) and match the opening degree of the solenoid valve (304); Only the solenoid valve (304) of the branch pipe corresponding to the defect is opened, while the other branches remain closed, so as to achieve point-to-point and quantitative adaptive glazing repair.

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