A hot-dip galvanizing metal fitting coating uniformity adaptive control system and device

Abstract

The application relates to the technical field of hot galvanizing, and discloses a hot galvanizing metal fitting coating uniformity self-adaptive control system and equipment, which solves the problem of poor control effect of the coating uniformity of metal fittings, and comprises a zinc pot, the bottom sides of the zinc pot are fixedly connected with support plates, a stirring mechanism is arranged on the zinc pot, the stirring mechanism comprises a bottom plate located below the zinc pot, the bottom plate is fixedly sleeved on the outer sides of the two support plates, a driving motor is fixedly installed on the top of the bottom plate, a driving shaft is fixedly connected with the driving motor, the top end of the driving shaft extends into the zinc pot, a sleeve plate located in the zinc pot is fixedly sleeved on the outer side of the driving shaft, a plurality of flow guide fins are fixedly connected with the outer side of the sleeve plate at equal angles, and a plurality of driven shafts are rotationally connected with the top of the bottom plate at equal angles; the metal fitting can continuously swing left and right, so that the control effect of the coating uniformity of the metal fitting can be improved.

Description

Technical Field

[0001] This invention belongs to the field of hot-dip galvanizing technology, specifically an adaptive control system and equipment for the coating uniformity of hot-dip galvanized metal parts. Background Technology

[0002] Hot-dip galvanized metal fittings refer to various steel hardware components such as angle steel, pipe joints, supports, and standard parts. They are widely used in outdoor and corrosive environments such as power, municipal, chemical, and transportation industries. Metal substrates exposed to humid, acidic, and alkaline environments for a long time are prone to corrosion and failure. The industry generally uses hot-dip galvanizing to treat fittings for corrosion protection. By immersing the metal fittings in molten zinc at 440℃-460℃, a dense zinc-iron alloy protective coating is formed on the surface of the workpiece, thereby extending the service life of the components. The uniformity of the coating is the core indicator for judging the quality of galvanized finished products. Excessive deviation in coating thickness will result in defects such as localized missed coating, zinc nodules, and failure to meet the anti-corrosion service life. Therefore, the industry generally uses segmented intelligent air knives, which adaptively adjust the air pressure of each segment based on online coating detection data to differentially blow away excess zinc liquid from the surface of the workpiece, thereby improving the uniformity of the coating surface.

[0003] The existing adaptive control scheme relying solely on segmented air knives has inherent shortcomings. The zinc pots used in hot-dip galvanizing production lines are deep, and the zinc liquid is prone to significant stratification when left to stand for a long time. The bottom area of ​​the pot is rich in iron and zinc impurities, has a lower temperature, and higher zinc liquid viscosity, while the upper layer of zinc liquid has a higher temperature, higher aluminum concentration, and better fluidity. When the metal parts are fully immersed in the zinc liquid, the upper and middle parts of the workpiece contact the upper and middle layers of zinc liquid respectively, while the bottom of the workpiece is in contact with the lower layer of low-temperature, high-impurity zinc liquid. There are natural differences in the temperature, composition, and viscosity of the zinc liquid in contact with different parts of the workpiece. Even if the air knife can purge and control the surface zinc liquid after the workpiece is removed from the pot, it cannot eliminate the difference in the amount of zinc on the substrate caused by zinc liquid stratification during the immersion process. In the final product, there is still a problem of uneven coating thickness between the upper and lower parts of the same workpiece. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the present invention provides an adaptive control system and equipment for the coating uniformity of hot-dip galvanized metal parts, which effectively solves the problem of poor control effect of coating uniformity of metal parts.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an adaptive control system for the coating uniformity of hot-dip galvanized metal fittings, comprising the following steps:

[0006] Step 1: First, start the hydraulic cylinder to lower the workpiece lifting plate until the metal parts are immersed in the molten zinc in the zinc pot;

[0007] Step 2: Then start the drive motor to rotate the stirring blades and guide vanes to agitate the zinc liquid. At the same time, the workpiece hanging plate moves the metal parts left and right continuously. Finally, the rear air knife is used for adaptive adjustment to further improve the uniformity of the coating.

[0008] An adaptive control device for the coating uniformity of hot-dip galvanized metal fittings includes a zinc pot, with support plates fixedly connected to both sides of the bottom of the zinc pot, and a stirring mechanism provided on the zinc pot.

[0009] The stirring mechanism includes a base plate located below the zinc pot, which is fixedly sleeved on the outside of two support plates. A drive motor is fixedly installed on the top of the base plate, and a drive shaft is fixedly connected to the drive motor. The top end of the drive shaft extends into the zinc pot, and a sleeve plate located inside the zinc pot is fixedly sleeved on the outside of the drive shaft. Multiple guide vanes are fixedly connected at equal angles on the outside of the sleeve plate. Multiple driven shafts are rotatably connected at equal angles on the top of the base plate. The top end of each driven shaft extends into the zinc pot, and multiple stirring blades located inside the zinc pot are fixedly connected to the outside of each driven shaft.

[0010] Preferably, a second bracket located outside the zinc pot is fixedly installed on the outer side of the drive shaft, and a drive gear is fixedly connected to the outer side of the second bracket. A first bracket located outside the zinc pot is fixedly installed on the outer side of each driven shaft, and a driven gear is fixedly connected to the outer side of each first bracket. Each driven gear meshes with the drive gear.

[0011] Preferably, a lifting plate is provided above the zinc pot, and guide rods are fixedly connected to both sides of the bottom of the lifting plate, with a stirring blade movably sleeved between the two guide rods.

[0012] Preferably, the bottom of the lifting plate is rotatably connected to a support shaft, the bottom end of the support shaft is fixedly connected to a chassis, the bottom of the chassis is rotatably connected to a movable rod, and the end of the movable rod away from the chassis is rotatably connected to the workpiece lifting plate.

[0013] Preferably, the bottom of the lifting plate is rotatably connected to a top shaft, and an upper conveyor belt is driven between the top shaft and the support shaft. The top of the bottom plate is rotatably connected to a bottom shaft, and a lower conveyor belt is driven between the bottom shaft and the drive shaft.

[0014] Preferably, a square frame is fixedly connected to the top end of the bottom shaft, and a square rod is fixedly connected to the bottom end of the top shaft, with the square rod inserted into the square frame.

[0015] Preferably, two columns are symmetrically fixedly connected to the top of the zinc pot on both sides, and a top plate is fixedly connected between the tops of each column. A hydraulic cylinder is fixedly installed at the bottom of the top plate, and the top of the lifting plate is fixed to the output end of the hydraulic cylinder, and the lifting plate is movably sleeved on the outside of each column.

[0016] Preferably, the zinc pot is provided with a perforated protective cylinder inside, and each stirring blade is located on the outside of the perforated protective cylinder. A perforated protective plate is fixedly connected to the bottom of the perforated protective cylinder. Multiple support columns are fixedly connected at equal angles between the bottom of the perforated protective plate and the inner wall of the zinc pot. The perforated protective plate is located above the sleeve plate.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] 1. This invention, by starting the drive motor, can drive the guide vanes to rotate, which can continuously send the upper layer of zinc liquid in the zinc pot to the lower layer. At the same time, it can make each stirring blade rotate to continuously stir the zinc liquid. Through the cooperation between the square rod and the square frame, it can drive the support shaft to rotate, which can facilitate the workpiece hanging plate to move back and forth along the two guide round rods, and make the metal parts swing left and right continuously, thereby improving the control effect of the coating uniformity of the metal parts.

[0019] 2. This invention enables the lifting plate to slide along each column by activating the hydraulic cylinder, facilitating the longitudinal movement of the workpiece hanging plate and thus making it easier to lift and lower the metal parts hanging at the bottom of the workpiece hanging plate.

[0020] 3. This invention, through the cooperation between the perforated protective cylinder and the perforated protective plate, can prevent the metal parts from colliding with the stirring blade and the guide vane during the lifting process, thereby facilitating the normal operation of the stirring blade and the guide vane. Attached Figure Description

[0021] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0022] In the attached diagram:

[0023] Figure 1 This is a schematic diagram of the adaptive control device for the coating uniformity of hot-dip galvanized metal parts according to the present invention.

[0024] Figure 2 This is a schematic cross-sectional view of the zinc pot of the present invention;

[0025] Figure 3 This is a schematic diagram of the hollowed-out protective cylinder structure of the present invention;

[0026] Figure 4 This is a schematic diagram of the stirring mechanism of the present invention;

[0027] Figure 5 This is a schematic diagram of the drive shaft structure of the present invention;

[0028] Figure 6 This is a schematic diagram of the workpiece lifting plate structure of the present invention;

[0029] Figure 7This is a schematic diagram of the connection structure between the top shaft and the bottom shaft of the present invention.

[0030] In the diagram: 1. Zinc pot; 2. Stirring mechanism; 201. Base plate; 202. Drive shaft; 203. Workpiece lifting plate; 204. Top shaft; 205. Bottom shaft; 206. Lower conveyor belt; 207. Drive motor; 208. Drive gear; 209. Driven gear; 2010. Support 1; 2011. Support 2; 2012. Driven shaft; 2013. Stirring blade; 2014. Sleeve plate; 2015. Guide vane; 2016. Chassis; 2017. Support shaft; 2018. Movable rod; 2019. Guide rod; 2020. Lifting plate; 2021. Column; 2022. Top plate; 2023. Hydraulic cylinder; 2024. Upper conveyor belt; 2025. Square rod; 2026. Square frame; 3. Hollowed-out protective cylinder; 4. Support plate; 5. Hollowed-out protective plate; 6. Support column. Detailed Implementation

[0031] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0032] Example 1, by Figures 1-7 The present invention relates to an adaptive control device for the coating uniformity of hot-dip galvanized metal fittings, comprising a zinc pot 1, with support plates 4 fixedly connected to both sides of the bottom of the zinc pot 1, and a stirring mechanism 2 provided on the zinc pot 1.

[0033] In Example 2, based on Example 1, the stirring mechanism 2 includes a bottom plate 201 located below the zinc pot 1. The bottom plate 201 is fixedly sleeved on the outside of two support plates 4. A drive motor 207 is fixedly installed on the top of the bottom plate 201. A drive shaft 202 is fixedly connected to the drive motor 207. The top end of the drive shaft 202 extends into the zinc pot 1. A sleeve plate 2014 located inside the zinc pot 1 is fixedly sleeved on the outside of the drive shaft 202. Multiple guide vanes 2015 are fixedly connected at equal angles to the outside of the sleeve plate 2014. The bottom plate 201... Multiple driven shafts 2012 are rotatably connected at the top, with the top of each driven shaft 2012 extending into the zinc pot 1. Multiple stirring blades 2013 located inside the zinc pot 1 are fixedly connected to the outer side of each driven shaft 2012. A second bracket 2011 located outside the zinc pot 1 is fixedly installed on the outer side of the drive shaft 202. A drive gear 208 is fixedly connected to the outer side of the second bracket 2011. A first bracket 2010 located outside the zinc pot 1 is fixedly installed on the outer side of each driven shaft 2012. The outer side of each first bracket 2010... A driven gear 209 is fixedly connected, and each driven gear 209 meshes with a driving gear 208. A lifting plate 2020 is provided above the zinc pot 1. Guide rods 2019 are fixedly connected to both sides of the bottom of the lifting plate 2020. A stirring blade 2013 is movably sleeved between the two guide rods 2019. A support shaft 2017 is rotatably connected to the bottom of the lifting plate 2020. A chassis 2016 is fixedly connected to the bottom end of the support shaft 2017. A movable rod 2018 is rotatably connected to the bottom of the chassis 2016. The end away from the chassis 2016 is rotatably connected to the workpiece lifting plate 203. The bottom of the lifting plate 2020 is rotatably connected to the top shaft 204. The top shaft 204 and the support shaft 2017 are connected by an upper conveyor belt 2024. The top of the base plate 201 is rotatably connected to the bottom shaft 205. The bottom shaft 205 and the drive shaft 202 are connected by a lower conveyor belt 206. The top of the bottom shaft 205 is fixedly connected to a square frame 2026. The bottom of the top shaft 204 is fixedly connected to a square rod 2025. The square rod 2025 is inserted into the square frame 2026.

[0034] First, the metal fittings hanging at the bottom of the workpiece hanging plate 203 are immersed in the zinc liquid in the zinc pot 1. Then, the drive motor 207 is started, which drives the drive shaft 202 to rotate. Through the sleeve plate 2014, the guide vanes 2015 are rotated, continuously sending the upper layer of zinc liquid in the zinc pot 1 to the lower layer. Since each driven gear 209 meshes with the drive gear 208, each driven shaft 2012 rotates, and at the same time, each stirring blade 2013 rotates to continuously stir the zinc liquid.

[0035] When the drive shaft 202 rotates, it drives the bottom shaft 205 to rotate via the lower conveyor belt 206. Since the square rod 2025 is movably connected to the square frame 2026, it drives the top shaft 204 to rotate, which in turn drives the support shaft 2017 to rotate via the upper conveyor belt 2024. At the same time, the chassis 2016 rotates, and then the movable rod 2018 drives the workpiece hanging plate 203 to reciprocate along the two guide rods 2019. Meanwhile, the metal parts swing left and right to quickly mix the different areas of the zinc liquid in the zinc pot 1 and eliminate the temperature difference between the top and bottom and left and right sides of the zinc pot 1. The process uniformly disperses the aluminum, rare earth, and other alloy components added to the zinc bath, avoiding local component segregation. It also breaks the layering state formed by the zinc bath during stagnation, ensuring that the viscosity and impurity content of the bottom and surface zinc bath of the zinc pot 1 are consistent. When metal parts are immersed, each part comes into contact with the zinc bath with uniform physical and chemical properties, reducing coating thickness deviations caused by differences in zinc bath conditions from the source of immersion plating. It can also accelerate the suspension and dispersion of a small amount of newly formed zinc dross, reduce the local zinc dross accumulation and adhesion to the workpiece to form zinc nodules, stabilize the basic zinc coating amount of the workpiece, and further improve the uniformity of the finished coating by cooperating with the adaptive adjustment of the air knife at the back end.

[0036] In Example 3, based on Example 1, two columns 2021 are symmetrically fixedly connected to both sides of the top of the zinc pot 1. A top plate 2022 is fixedly connected between the tops of each column 2021. A hydraulic cylinder 2023 is fixedly installed at the bottom of the top plate 2022. The top of the lifting plate 2020 is fixed to the output end of the hydraulic cylinder 2023, and the lifting plate 2020 is movably sleeved on the outside of each column 2021.

[0037] First, the hydraulic cylinder 2023 is activated, which drives the lifting plate 2020 to slide along each column 2021, and drives the hydraulic cylinder 2023 to move longitudinally, finally realizing the lifting and lowering of the metal parts hanging at the bottom of the workpiece hanging plate 203.

[0038] In Example 4, based on Example 1, the zinc pot 1 is provided with a hollow protective cylinder 3 inside. Each stirring blade 2013 is located on the outside of the hollow protective cylinder 3. A hollow protective plate 5 is fixedly connected to the bottom of the hollow protective cylinder 3. Multiple support columns 6 are fixedly connected at equal angles between the bottom of the hollow protective plate 5 and the inner wall of the zinc pot 1. The hollow protective plate 5 is located above the sleeve plate 2014.

[0039] When the hydraulic cylinder 2023 is activated, the metal parts descend into the hollow protective cylinder 3 and are positioned above the hollow protective plate 5, thus shielding the stirring blade 2013 and the guide vane 2015 and preventing the metal parts from colliding with the stirring blade 2013 and the guide vane 2015 during the lifting and lowering process.

Claims

1. An adaptive control system for the uniformity of coating on hot-dip galvanized metal fittings, characterized in that: Includes the following steps: Step 1: First, start the hydraulic cylinder (2023) to drive the workpiece lifting plate (203) down until the metal parts are immersed in the zinc liquid in the zinc pot (1); Step 2: Then start the drive motor (207) to drive the stirring blade (2013) and the guide vane (2015) to rotate and stir the zinc liquid. At the same time, the workpiece hanging plate (203) drives the metal parts to swing left and right continuously. Finally, the rear air knife is used for adaptive adjustment to further improve the coating uniformity.

2. An adaptive control device for the uniformity of coating on hot-dip galvanized metal fittings, comprising a zinc pot (1), characterized in that: The zinc pot (1) is fixedly connected to both sides of the bottom with support plates (4), and the zinc pot (1) is equipped with a stirring mechanism (2). The stirring mechanism (2) includes a bottom plate (201) located below the zinc pot (1). The bottom plate (201) is fixedly sleeved on the outside of two support plates (4). A drive motor (207) is fixedly installed on the top of the bottom plate (201). A drive shaft (202) is fixedly connected to the drive motor (207). The top end of the drive shaft (202) extends into the zinc pot (1). A sleeve plate (2014) located in the zinc pot (1) is fixedly sleeved on the outside of the drive shaft (202). Multiple guide vanes (2015) are fixedly connected at equal angles on the outside of the sleeve plate (2014). Multiple driven shafts (2012) are rotatably connected at equal angles on the top of the bottom plate (201). The top end of each driven shaft (2012) extends into the zinc pot (1). Multiple stirring blades (2013) located in the zinc pot (1) are fixedly connected on the outside of each driven shaft (2012).

3. The adaptive control device for coating uniformity of hot-dip galvanized metal fittings according to claim 2, characterized in that: The outer side of the drive shaft (202) is fixedly installed with a bracket two (2011) located outside the zinc pot (1). The outer side of the bracket two (2011) is fixedly connected with a drive gear (208). The outer side of each driven shaft (2012) is fixedly installed with a bracket one (2010) located outside the zinc pot (1). The outer side of each bracket one (2010) is fixedly connected with a driven gear (209). Each driven gear (209) meshes with the drive gear (208).

4. The adaptive control device for coating uniformity of hot-dip galvanized metal fittings according to claim 2, characterized in that: The zinc pot (1) is provided with a lifting plate (2020) above it. Guide rods (2019) are fixedly connected to both sides of the bottom of the lifting plate (2020). A stirring blade (2013) is movably sleeved between the two guide rods (2019).

5. The adaptive control device for coating uniformity of hot-dip galvanized metal fittings according to claim 4, characterized in that: The bottom of the lifting plate (2020) is rotatably connected to a support shaft (2017), the bottom end of the support shaft (2017) is fixedly connected to a chassis (2016), the bottom of the chassis (2016) is rotatably connected to a movable rod (2018), and the end of the movable rod (2018) away from the chassis (2016) is rotatably connected to the workpiece lifting plate (203).

6. The adaptive control device for coating uniformity of hot-dip galvanized metal fittings according to claim 4, characterized in that: The bottom of the lifting plate (2020) is rotatably connected to a top shaft (204), and an upper conveyor belt (2024) is driven between the top shaft (204) and the support shaft (2017). The top of the bottom plate (201) is rotatably connected to a bottom shaft (205), and a lower conveyor belt (206) is driven between the bottom shaft (205) and the drive shaft (202).

7. The adaptive control device for coating uniformity of hot-dip galvanized metal fittings according to claim 6, characterized in that: The top end of the bottom shaft (205) is fixedly connected to a square frame (2026), and the bottom end of the top shaft (204) is fixedly connected to a square rod (2025), which is inserted into the square frame (2026).

8. The adaptive control device for coating uniformity of hot-dip galvanized metal fittings according to claim 2, characterized in that: The zinc pot (1) has two columns (2021) symmetrically fixedly connected on both sides of the top. A top plate (2022) is fixedly connected between the tops of each column (2021). A hydraulic cylinder (2023) is fixedly installed at the bottom of the top plate (2022). The top of the lifting plate (2020) is fixed to the output end of the hydraulic cylinder (2023), and the lifting plate (2020) is movably sleeved on the outside of each column (2021).

9. The adaptive control device for coating uniformity of hot-dip galvanized metal fittings according to claim 1, characterized in that: The zinc pot (1) is provided with a hollow protective cylinder (3) inside. Each stirring blade (2013) is located on the outside of the hollow protective cylinder (3). A hollow protective plate (5) is fixedly connected to the bottom of the hollow protective cylinder (3). Multiple support columns (6) are fixedly connected at equal angles between the bottom of the hollow protective plate (5) and the inner wall of the zinc pot (1). The hollow protective plate (5) is located above the sleeve plate (2014).

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