Intelligent control system for plasma spraying

Abstract

The utility model provides an intelligent control system for plasma spraying, which belongs to the technical field of spraying and comprises a control cabinet, and the control cabinet is used for controlling and monitoring a power supply cabinet, a gas management center, a powder feeder, a transfer box, a spray gun and a cooling unit. The power supply cabinet is connected with the spray gun through the transfer box and is used for generating plasma; the gas management center comprises a gas carrying pipeline, a plurality of gas pipes and a gas mixing structure, the gas carrying pipeline and the gas pipes are connected into the gas mixing structure, and the gas mixing structure is connected with the spray gun through a transfer box and used for providing plasma gas; the gas carrying pipeline is further provided with a branch pipe, and the branch pipe is communicated with the powder feeder. According to the scheme, the production data is monitored in real time, the parameters are dynamically corrected based on the production data, manual intervention is reduced, the amplitude threshold is adjusted according to the set parameters of all the components, sound-light alarm is triggered when the parameters exceed the set range, equipment overload is prevented, early fault positioning is achieved for key parameters of all the components, and the shutdown risk is reduced.

Description

Technical Field

[0001] This utility model relates to the field of spraying technology, specifically to an intelligent control system for plasma spraying. Background Technology

[0002] Plasma spraying technology uses high-temperature plasma to melt and deposit sprayed materials onto the surface of a substrate. It is widely used in aerospace, automotive manufacturing, and other fields, where extremely high requirements are placed on coating quality and process stability. In recent years, with the advancement of Industry 4.0 and intelligent manufacturing, plasma spraying technology has evolved from integrated touchscreen interfaces to automated control that uses sensors to monitor parameters such as spraying temperature and speed in real time and feeds this information back to the control system for adjustment.

[0003] Nevertheless, existing technologies still have some shortcomings. The various subsystems of existing plasma spraying technologies (such as powder feeding, power supply, and gas management) often operate independently or in simple linkage, lacking cross-component parameter control linkage. The alarm mechanisms are mostly passive response control, lacking fault prediction and adaptive adjustment capabilities, which can easily lead to the risk of cascading shutdowns. Utility Model Content

[0004] The purpose of this invention is to provide an intelligent control system for plasma spraying to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] An intelligent control system for plasma spraying includes: a control cabinet for controlling and monitoring a power supply cabinet, a gas management center, a powder feeder, a transfer box, a spray gun, and a cooling unit; the power supply cabinet is connected to the spray gun via the transfer box and is used to generate plasma; the gas management center includes a carrier gas pipeline, several gas pipes, and a gas mixing structure, the carrier gas pipeline and several gas pipes being connected to the gas mixing structure, and the gas mixing structure being connected to the spray gun via the transfer box and used to provide plasma gas; the carrier gas pipeline also has a branch pipe connected to the powder feeder; the powder feeder is connected to the spray gun via a powder feeding pipeline and is used to deliver powder to the spray gun nozzle using the carrier gas; the cooling unit is connected to the spray gun via the transfer box and is used to dissipate heat and protect the spray gun.

[0007] Preferably, powder hose connectors are symmetrically installed on both sides of the nozzle of the spray gun. The powder hose connectors are connected to the powder feeding pipeline of the powder feeder. A positive electrode connection is provided on the body of the spray gun, and a negative electrode connection and a plasma gas connector are provided at the end of the body away from the nozzle. The positive electrode connection is also used as a cooling circulation inlet, and the negative electrode connection is used as a cooling circulation outlet.

[0008] Preferably, the controlled parameters of the power supply cabinet include input voltage, input current, output voltage, output current, cabinet internal temperature, and cooling fan speed.

[0009] Preferably, the controlled parameters of the gas management center include gas pressure, gas flow rate, and gas pipeline switch.

[0010] Preferably, the controlled parameters of the powder feeder include the powder feeding disc speed, stirring speed, powder feeding gas pressure, powder feeding gas flow rate, and powder weight variation.

[0011] Preferably, the controlled parameters of the transfer box include inlet water temperature, return water temperature, return water flow rate, water conductivity, and gas pressure.

[0012] Preferably, the controlled parameters of the spray gun include operating voltage, operating current, and operating power.

[0013] Preferably, the controlled parameters of the cooling unit include operating voltage, operating current, outlet water flow rate, outlet water temperature, return water flow rate, return water temperature, and cooling water pump protection operation.

[0014] Preferably, the power cabinet, gas management center, powder feeder, transfer box, spray gun and cooling unit are all equipped with alarm mechanisms.

[0015] Preferably, the alarm information of the power supply cabinet includes overvoltage, overcurrent, overtemperature protection and inverter IGBT driver board protection; the alarm information of the gas management center includes abnormal gas pressure, abnormal gas flow, and pipeline switch failure; the alarm information of the powder feeder includes abnormal gas pressure, abnormal powder feeding motor speed, abnormal stirring motor speed, abnormal powder feeding weight, powder shortage alarm, abnormal powder feeding motor driver, and abnormal stirring motor driver; the alarm information of the transfer box includes abnormal inlet water temperature, excessively high return water temperature, abnormal return water flow, and abnormal water conductivity; the alarm information of the spray gun includes overvoltage and abnormal power; and the alarm information of the cooling unit includes abnormal outlet water flow, abnormal outlet water temperature, abnormal return water flow, abnormal return water temperature, and cooling water pump failure.

[0016] The beneficial effects of the above-mentioned technical solution of this utility model are as follows:

[0017] This solution integrates seven components: control cabinet, power cabinet, gas management center, powder feeder, transfer box, spray gun, and cooling unit. It monitors production data in real time and dynamically corrects parameters based on the production data, reducing manual intervention. It adjusts the threshold range of parameter settings for each component and triggers audible and visual alarms when the parameters exceed the set range to prevent equipment overload. It also enables early fault location for key parameters of each component, reducing the risk of downtime. Attached Figure Description

[0018] The above and other objects, features, and advantages of the present invention will become readily understood by reading the following detailed description of exemplary embodiments with reference to the accompanying drawings. In the drawings, several embodiments of the present invention are shown by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein:

[0019] Figure 1 This is a schematic diagram of the communication connection of this utility model;

[0020] Figure 2 This is a schematic diagram of the operation process of this utility model;

[0021] Figure 3 This is a schematic diagram of the gas management center of this utility model;

[0022] Figure 4 This is a schematic diagram of the spray gun structure of this utility model.

[0023] Explanation of reference numerals in the attached figures:

[0024] 1. Control cabinet; 11. Control cabinet panel; 2. Power supply cabinet; 3. Gas management center; 31. Carrier gas pipeline; 32. Carrier gas branch pipe; 33. Plasma gas pipeline; 34. Gas conditioning structure; 35. Gas mixing structure; 4. Powder feeder; 41. Powder feeding control panel; 42. Powder feeding pipeline; 5. Adapter box; 6. Spray gun; 61. Powder hose connector; 62. Cooling circulation inlet; 63. Cooling circulation outlet; 64. Positive connection; 65. Negative connection; 66. Plasma gas interface; 7. Cooling unit. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Those skilled in the art should understand that the embodiments described below are only some, not all, of the embodiments disclosed. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0026] This solution achieves efficient and stable operation of the spraying process through architecture integration, dynamic monitoring, intelligent control, and fault early warning. The system integrates seven core components, including control cabinets and power cabinets, to build a unified data monitoring network, breaking away from the traditional independent operation mode of subsystems and enabling cross-component parameter linkage. During operation, the system monitors the key parameters of each component in real time throughout the entire process. If a single component parameter becomes abnormal, it automatically adjusts based on the component's production data rules and generates a report; simultaneously, based on overall production data, it proactively triggers collaborative optimization of multi-component parameters.

[0027] This solution sets adjustment thresholds for each parameter, automatically adjusting within the thresholds and triggering a fatal error audible and visual alarm if the threshold is exceeded to prevent equipment overload. Unlike traditional passive alarms, this system analyzes parameter fluctuation trends to predict potential faults, enabling early intervention. It can also accurately locate faults based on independent monitoring data, reducing downtime risks. Furthermore, the system reduces manual intervention through automated monitoring and adjustment while retaining a manual intervention interface, forming a flexible control mode that is intelligently driven and manually assisted, comprehensively improving the reliability and efficiency of plasma spraying production.

[0028] After introducing the basic principles of this utility model, various non-limiting embodiments of this utility model are described in detail below. Any quantity of elements in the accompanying drawings is for illustrative purposes only and not for limitation, and any naming is for distinction only and has no limiting meaning.

[0029] The principles and spirit of this utility model will be explained in detail below with reference to several representative embodiments. Example

[0030] An intelligent control system for plasma spraying, such as Figure 1-4 As shown, the system includes a control cabinet 1, a power supply cabinet 2, a gas management center 3, a powder feeder 4, a transfer box 5, a spray gun 6, and a cooling unit 7. The control cabinet 1 is connected to the power supply cabinet 2, the gas management center 3, the powder feeder 4, the transfer box 5, and the cooling unit 7 via communication. In this embodiment, the control cabinet 1 has a control cabinet panel 11, and the powder feeder 4 has a powder feeding panel. The control cabinet 1, control cabinet panel 11, powder feeder 4, and powder feeding control panel 41 are sequentially connected via Ethernet communication. The control cabinet 1 is connected to the gas management center 3, the power supply cabinet 2, the transfer box 5, and the cooling unit 7 via discrete digital signals. The control cabinet 1 is used to control and monitor the parameters of the power supply cabinet 2, the gas management center 3, the powder feeder 4, the transfer box 5, the spray gun 6, and the cooling unit 7, and to trigger an alarm on the corresponding equipment when parameters are abnormal.

[0031] like Figure 2 and Figure 3 As shown, the power supply cabinet 2 is electrically connected to the adapter box 5 and the spray gun 6 in sequence. The power supply cabinet 2 is used to convert the current and let it flow into the spray gun 6 through the adapter box 5. The gas management center 3 is used to control and monitor the gas in the spraying system. The gas management center 3 includes a carrier gas pipeline 31, several plasma gas pipes 33 and a gas mixing structure 35. The carrier gas pipeline 31 and several gas pipes are also equipped with a gas regulating structure 34. The carrier gas and other gases enter the gas mixing structure 35 through the carrier gas pipeline 31 and gas pipes respectively through the gas regulating structure 34, mix into plasma gas, and then send it into the spray gun 6 through the adapter box 5 via a hose. Together with the current converted by the power supply cabinet 2, plasma is generated.

[0032] On the carrier gas pipeline 31, before the gas regulating structure 34, there is also a carrier gas branch pipe 32. The carrier gas branch pipe 32 is connected to the powder feeder 4 and is used to deliver carrier gas into the powder feeder 4. The powder feeder 4 includes a stirring motor, a powder bucket, a stirring assembly, a weighing assembly, a powder feeding assembly, a conveying motor assembly, a control circuit, and a gas control assembly. The powder feeder 4 is existing technology and will not be described in detail here. The powder feeding assembly of the powder feeder 4 is connected to the powder feeding pipeline 42. The powder feeder 4 is connected to the powder hose connectors 61 symmetrically installed on both sides of the nozzle of the spray gun 6 through the powder feeding pipeline 42. It is used to deliver the powder coating to the nozzle of the spray gun 6 using carrier gas to ensure conveying efficiency and conveying stability.

[0033] like Figure 2 and Figure 4 As shown, the cooling unit 7 is connected to the spray gun 6 via the adapter box 5, and is used for heat dissipation and protection of the spray gun 6. In this embodiment, the cooling unit 7 is a water-cooled unit. The spray gun 6 can be handheld or mechanically mounted. The end of the spray gun 6 away from the nozzle is provided with a cooling circulation inlet 62 and a cooling circulation outlet 63, which are respectively connected to the water-cooled unit via the adapter box 5 to form a complete cooling circulation channel.

[0034] Specifically, the cooling circulation inlet 62 and the cooling circulation outlet 63 are spirally fixed on the spray gun 6 body. The cooling circulation inlet 62 is located on the outside of the gun body and also serves as the positive terminal connection 64. The cooling circulation outlet 63 is located inside the gun body and also serves as the negative terminal connection 65. The positive terminal connection 64 and the negative terminal connection 65 are respectively connected to the positive and negative terminal channels of the power cabinet 2 through the adapter box 5 to form a strong electric field. A plasma gas interface 66 is also fixedly installed inside the spray gun 6. The front end of the plasma gas interface 66 extends into the gun body. The plasma gas delivered by the gas mixing structure 35 is ionized under the action of the strong electric field to form high-temperature and high-energy plasma, which drives the coating to atomize into tiny particles. These particles are negatively charged and are electrostatically adsorbed onto the workpiece surface. After cooling and solidification, a dense and highly adhesive coating is formed, completing the spraying process.

[0035] This intelligent control system monitors the control parameters and alarm information of each component throughout the entire process. When an anomaly occurs, it automatically adjusts the control parameters of each component based on the component's production data. Simultaneously, this system can proactively adjust the control parameters of multiple components automatically based on overall production data requirements, generating adjustment reports. The system includes adjustable parameter values; if these values ​​are exceeded, the intelligent control system outputs a fatal error alarm, accompanied by audible and visual alarms.

[0036] Specifically, the controlled parameters of power cabinet 2 include input voltage, input current, output voltage, output current, cabinet temperature, and cooling fan speed. Alarm information includes overvoltage, overcurrent, overtemperature protection, and inverter IGBT driver board protection. The controlled parameters of gas management center 3 include gas pressure, gas flow rate, and gas pipeline switch. Alarm information includes abnormal gas pressure, abnormal gas flow rate, and pipeline switch failure. The controlled parameters of powder feeder 4 include powder feeding disc speed, stirring speed, powder feeding gas pressure, powder feeding gas flow rate, and powder weight change. Alarm information includes abnormal gas pressure, abnormal powder feeding motor speed, abnormal stirring motor speed, abnormal powder feeding weight, and powder shortage alarm. The following alarms were triggered: 1. Abnormalities in the powder feeding motor driver and 2. Abnormalities in the stirring motor driver; 3. Controlled parameters of the transfer box 5 include inlet water temperature, return water temperature, return water flow rate, water conductivity, and gas pressure. Alarm information includes abnormal inlet water temperature, excessively high return water temperature, low return water flow rate, and excessively high water conductivity; 4. Controlled parameters of the spray gun 6 include operating voltage, operating current, and operating power. Alarm information includes overvoltage and abnormal power; 5. Controlled parameters of the cooling unit 7 include operating voltage, operating current, outlet water flow rate, outlet water temperature, return water flow rate, return water temperature, and cooling water pump protection action. Alarm information includes abnormal outlet water flow rate, abnormal outlet water temperature, abnormal return water flow rate, abnormal return water temperature, and cooling water pump malfunction.

[0037] The above-described preferred embodiments of the present invention are provided for guidance, but it will be apparent to those skilled in the art that such embodiments are provided merely by way of example. Many modifications, alterations, and alternatives will arise in the mind and spirit of the present invention without departing from its intent. It should be understood that various alternatives to the embodiments of the present invention described herein may be employed in the practice of the present invention. The appended claims are intended to define the scope of protection of the present invention and therefore cover the modular compositions, equivalents, or alternatives within the scope of these claims.

Claims

1. An intelligent control system for plasma spraying, characterized in that, include: The control cabinet (1) is used to control and monitor the power supply cabinet (2), gas management center (3), powder feeder (4), adapter box (5), spray gun (6), and cooling unit (7); the power supply cabinet (2) is connected to the spray gun (6) through the adapter box (5) to generate plasma; the gas management center (3) includes a carrier gas pipeline (31), several gas pipes, and a gas mixing structure (35), the carrier gas pipeline (31) and several gas pipes being connected to the gas mixing structure. The gas mixing structure (35) is connected to the spray gun (6) through the adapter box (5) to provide plasma gas; the carrier gas pipeline (31) is also provided with a branch pipe, which is connected to the powder feeder (4); the powder feeder (4) is connected to the spray gun (6) through the powder feeding pipeline (42) to use the carrier gas to send powder to the nozzle of the spray gun (6); the cooling unit (7) is connected to the spray gun (6) through the adapter box (5) to dissipate heat and protect the spray gun (6).

2. The intelligent control system for plasma spraying according to claim 1, characterized in that: The spray gun (6) has powder hose connectors (61) symmetrically installed on both sides of the nozzle. The powder hose connectors (61) are connected to the powder feeding pipe (42) of the powder feeder (4). The spray gun (6) has a positive electrode connection (64) on its body and a negative electrode connection (65) and a plasma gas connector on the end of the body away from the nozzle. The positive electrode connection (64) is also used as a cooling circulation inlet (62), and the negative electrode connection (65) is used as a cooling circulation outlet (63).

3. The intelligent control system for plasma spraying according to claim 1, characterized in that: The controlled parameters of the power cabinet (2) include input voltage, input current, output voltage, output current, cabinet temperature and cooling fan speed.

4. The intelligent control system for plasma spraying according to claim 1, characterized in that: The controlled parameters of the gas management center (3) include gas pressure, gas flow rate and gas pipeline switch.

5. The intelligent control system for plasma spraying according to claim 1, characterized in that: The controlled parameters of the powder feeder (4) include the powder feeding disc speed, stirring speed, powder feeding gas pressure, powder feeding gas flow rate and powder weight change.

6. The intelligent control system for plasma spraying according to claim 1, characterized in that: The controlled parameters of the junction box (5) include inlet water temperature, return water temperature, return water flow rate, water conductivity and gas pressure.

7. The intelligent control system for plasma spraying according to claim 1, characterized in that: The controlled parameters of the spray gun (6) include operating voltage, operating current and operating power.

8. The intelligent control system for plasma spraying according to claim 1, characterized in that: The controlled parameters of the cooling unit (7) include operating voltage, operating current, outlet water flow rate, outlet water temperature, return water flow rate, return water temperature, and cooling water pump protection action.

9. The intelligent control system for plasma spraying according to claim 1, characterized in that: The power cabinet (2), gas management center (3), powder feeder (4), transfer box (5), spray gun (6) and cooling unit (7) are all equipped with alarm mechanisms.

10. The intelligent control system for plasma spraying according to claim 9, characterized in that: The alarm information of the power cabinet (2) includes overvoltage, overcurrent, overtemperature protection and inverter IGBT driver board protection; the alarm information of the gas management center (3) includes abnormal gas pressure, abnormal gas flow and pipeline switch failure; the alarm information of the powder feeder (4) includes abnormal gas pressure, abnormal powder feeding motor speed, abnormal stirring motor speed, abnormal powder feeding weight, powder shortage alarm, abnormal powder feeding motor driver and abnormal stirring motor driver; the alarm information of the transfer box (5) includes abnormal inlet water temperature, excessively high return water temperature, abnormal return water flow and abnormal water conductivity; the alarm information of the spray gun (6) includes overvoltage and abnormal power; the alarm information of the cooling unit (7) includes abnormal outlet water flow, abnormal outlet water temperature, abnormal return water flow, abnormal return water temperature and abnormal cooling water pump failure.

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