Automatic, efficient and uniform spraying device for duct piece mold

Abstract

The utility model discloses an automatic high-efficiency uniform spraying device for a duct piece mould, which comprises a spraying device, a visual device, a dust collection device and a compatible flange, the full-automatic operation is realized through the carrying of an industrial robot, the spraying device comprises a hairbrush main body, a nozzle and a rotating platform, and after the nozzle sprays a release agent, the nozzle is driven to rotate by the rotating platform. The rotating platform drives the brush to uniformly smear; the visual device realizes mold positioning and spraying area detection through a calibration needle and an industrial camera; and the dust collection device synchronously adsorbs impurities in the air. During working, the robot plans a spraying path in combination with visual positioning, spraying, rotating and dust collecting actions are operated cooperatively, and after first-round spraying, a camera rechecks a missed-coating area and performs supplementary coating. The split type design is adopted, all the modules can be independently disassembled and maintained, the device is suitable for duct piece molds of different specifications, uniform smearing of a release agent is achieved, labor intensity and environmental hazards are remarkably reduced, and the device is suitable for the scene of batch production of the duct piece molds.

Description

Technical Field

[0001] This utility model belongs to the field of automated processing technology for tunnel segment molds, specifically relating to an automatic, efficient and uniform spraying device for tunnel segment molds. Background Technology

[0002] Currently, the application of release agent to the surface of segment molds generally relies on manual operation, which has the following significant drawbacks:

[0003] Uneven application: Manual use of tools such as brushes and scrapers makes it difficult to cover the edges and gaps of the mold, which affects the quality of subsequent concrete pouring.

[0004] The work is labor-intensive and unsafe: workers need to climb ladders to work at heights and bend over to operate, which limits the amount of work they can do per day. In addition, the volatile substances from the release agent and impurities in the air are harmful to the human body.

[0005] Low efficiency: Manual application requires frequent tool changes and posture adjustments, and each mold operation takes about 30 minutes, severely limiting the production cycle.

[0006] High maintenance costs: Manual operation relies on tool wear and tear (such as brush replacement), and the amount of release agent cannot be accurately controlled, resulting in material waste. Summary of the Invention

[0007] The purpose of this invention is to provide an automatic, efficient, and uniform spraying device for pipe segment molds to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, this utility model provides the following technical solution: an automatic, efficient, and uniform spraying device for segment molds, comprising a spraying device, a vision device, a dust extraction device, and a compatible flange;

[0009] The spraying device includes a brush body, a nozzle, a rotating platform, and a mounting flange. The nozzle passes through the brush body and is connected to the rotating platform. The rotating platform is connected to a compatible flange via the mounting flange.

[0010] The vision device includes a calibration needle and a camera, and is mounted side-by-side with the spraying device on one side of the compatible flange.

[0011] The dust collection device is installed on the other side of the compatible flange and is used to absorb impurities generated during the spraying process;

[0012] The compatible flange is used to integrate the spraying device, vision device and dust collection device, and adjusts the posture of the robot and truss to achieve all-round spraying of the segment mold.

[0013] Preferably, the nozzle includes an outer nozzle tube, a release agent conduit, and a transverse conduit. Two release agent conduits are located inside the outer nozzle tube, and the latter diameter is located inside the transverse conduit, with their liquid outlets facing each other. The transverse conduit extends transversely through the outer nozzle tube.

[0014] Preferably, the lateral nozzles of the nozzle are distributed radially along the brush body, the spray coverage angle is ≥270°, and the nozzle orifice diameter is 0.5-1mm.

[0015] Preferably, the calibration pins of the vision device are arranged side by side with the camera, and the camera is used to photograph the spraying state of the tube segment mold and determine the position of the mold through visual calibration.

[0016] Preferably, the rotating platform is driven by a motor to rotate the brush body around its own axis at a speed of 20-50 r / min. The brush body has a bristle density of ≥200 bristles / cm², so that the release agent is evenly coated on the surface of the tube mold.

[0017] Preferably, the compatible flange has a standardized interface to adapt to gantry robots of different specifications, enabling rapid installation and attitude adjustment of the device.

[0018] Preferably, the negative pressure fan of the dust collection device has an air volume of ≥1500m³ / h, and the filter assembly has an adsorption efficiency of ≥95% for release agent droplets.

[0019] The technical effects and advantages of this utility model are as follows:

[0020] 1. Improved coating uniformity: The rotating platform drives the brush body to rotate, combined with the release agent spraying from the horizontal nozzle, to achieve 360° coverage of the mold surface without dead angles, solving the problem of missed corners in manual coating.

[0021] 2. It realizes automated collaborative operation. The vision device (calibration needle + camera) locates the mold position in real time and feeds back to the control system. The robot adjusts the spraying posture in sync, realizing a fully automated operation process and replacing traditional manual operation.

[0022] 3. The three functional modules of spraying, dust collection and visual inspection work together. During spraying, the dust collection device simultaneously adsorbs release agent droplets and dust, and the vision system monitors the spraying quality in real time and triggers the re-spray mechanism, which shortens the single operation cycle by more than 40%.

[0023] 4. The spraying, vision, and dust extraction components are installed independently via compatible flanges. In case of failure, they can be disassembled and repaired individually without shutting down the entire machine, greatly improving maintenance efficiency. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of this utility model;

[0025] Figure 2 This is a schematic diagram of the spraying device.

[0026] Figures 3-4 This is a schematic diagram of the internal structure of the spraying device;

[0027] Figure 5 Figure showing the practical application of this utility model.

[0028] In the diagram: Spraying device-1, Vision device-2, Dust collection device-3, Compatible flange-4, 6-Segment mold, Truss-7, Brush body-101, Nozzle-102, Rotating platform-103, Mounting flange-104, Nozzle outer tube-1021, Release agent conduit-1022, Horizontal conduit-1023. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] like Figures 1-5 This invention illustrates a specific embodiment of an automatic, efficient, and uniform spraying device for segment molds: it consists of four main modules: a spraying device 1, a vision device 2, a dust extraction device 3, and a compatible flange 4. Each component is integrated into the end effector of an industrial robot via the compatible flange 4, forming a "three-in-one" split structure (e.g., ...). Figure 1 (As shown)

[0031] The brush body 101 of the spraying device 1 adopts a cylindrical nylon bristle structure with a bristle length of 20-30mm and a density of ≥200 bristles / cm², which is suitable for the flat, curved and corner areas of the tube sheet mold (6).

[0032] The nozzle 102 includes an outer nozzle tube 1021, a release agent conduit 1022, and a transverse conduit 1023, and is connected to an external release agent tank via a hose. The spraying angle is at a 45° angle to the direction of brush rotation.

[0033] The rotating platform 103 is driven by a stepper motor with an adjustable speed range of 20-50 r / min. It is coaxially connected to the brush body 101 via a coupling to ensure smooth rotation.

[0034] The mounting flange 104 has 4 sets of quick-release bolt holes. After connecting with the compatible flange 4, the eccentricity between the center line of the brush body 101 and the robot end axis is ≤10mm, ensuring motion accuracy.

[0035] The vision device consists of a calibration needle and an industrial camera. The calibration needle is 50mm long and has a conical end. It is used to contact the edge of the mold to achieve physical positioning and trigger a positioning signal. The industrial camera has a resolution of 5 megapixels and is installed at a height of 300-500mm from the mold surface. The shooting range covers a single mold side plate (approximately 3m × 1.5m in size) and supports RGB and depth image acquisition.

[0036] The dust collection device uses a negative pressure fan with an air volume of 1500m³ / h and a power of 1.5kW. It is connected to the dust collection port above the mold through a hose, forming a negative pressure field to adsorb the mist and dust generated during the spraying process. Its filtration component adopts a three-stage filtration (pre-filter + activated carbon layer + HEPA filter), with a filtration efficiency of ≥95% for particles ≥0.3μm. The filter element supports quick disassembly and replacement.

[0037] The compatible flange 4 has a "T" shaped structure, with a vision device 2 and a dust extraction device 3 installed at the two ends laterally, and a spraying device 1 connected to the center longitudinally. The spacing between each module is ≥100mm to avoid interference (e.g., ...). Figure 1 (As shown).

[0038] Taking the spraying operation of the side plate of the segment mold as an example (e.g.) Figure 5 (As shown), the specific process is as follows:

[0039] The segment mold 6 is conveyed to the spraying station by the conveyor belt. The calibration needle of the vision device 2 contacts the upper edge of the mold side plate, triggering the sensor to confirm that the mold is in place. At the same time, the robot coordinate system and the mold coordinate system are calibrated (error ≤ 1mm).

[0040] An industrial camera captures images of the mold side panel. An edge detection algorithm identifies feature points such as the side panel contour and bolt holes, generating a 3D spraying path (e.g., ...). Figure 5 (as shown)

[0041] The robot 7 drive unit moves to the front of the mold side plate and pauses at a distance of 200mm from the surface; the rotating platform 103 starts, and the brush body 101 pre-rotates at a speed of 30r / min for 5 seconds to ensure that the bristles are spread out.

[0042] The mold release agent conduit 1022 is opened, the pressure is 0.3MPa, and the mold release agent is sprayed in a mist form through the horizontal nozzle to the inside of the brush body 101, and is evenly carried to the mold surface by the rotating bristles.

[0043] Robot 7 moves along the length of the side plate at a speed of 200mm / s, and the brushes simultaneously cover the spraying area, with the thickness of a single spray controlled at 0.1-0.15mm;

[0044] When the corner area of ​​the mold is detected, robot 7 adjusts its posture to tilt the brush at 45° and increases the rotation speed of the rotating platform to 40 r / min, thereby increasing the contact pressure between the brush bristles and the corner to achieve full coverage;

[0045] The negative pressure fan starts simultaneously when the spraying begins, and the dust suction port is aimed at 200mm behind the brush to absorb the volatilized release agent droplets and dust on the mold surface in real time, so as to avoid polluting the workshop environment. After the first round of spraying is completed, the industrial camera takes another picture of the side panel and identifies the missed areas (such as areas with abnormal gray values) through pixel comparison algorithm. The robot automatically plans the recoating path and repeats the spraying until the inspection is qualified.

[0046] The applicant further declares that while the above embodiments illustrate the implementation method and apparatus structure of this utility model, this utility model is not limited to the above-described embodiments, meaning that this utility model must rely on the above methods and structures to be implemented. Those skilled in the art should understand that any improvements to this utility model, equivalent substitutions for the selected implementation methods, additions of steps, and selection of specific methods all fall within the protection and disclosure scope of this utility model.

[0047] This utility model is not limited to the above-described embodiments. All methods that use similar structures and methods to achieve the purpose of this utility model are within the protection scope of this utility model.

Claims

1. An automatic, efficient, and uniform spraying device for segment molds, characterized in that: Includes a spraying device (1), a vision device (2), a dust collection device (3), and a compatible flange (4); The spraying device (1) includes a brush body (101), a nozzle (102), a rotating platform (103) and a mounting flange (104). The nozzle (102) passes through the brush body (101) and is connected to the rotating platform (103). The rotating platform (103) is connected to a compatible flange (4) through the mounting flange (104). The vision device (2) includes a calibration needle and a camera, and is mounted side by side with the spraying device (1) on one side of the compatible flange (4); The dust collection device (3) is installed on the other side of the compatible flange (4) and is used to adsorb impurities generated during the spraying process; The compatible flange (4) is used to integrate the spraying device (1), vision device (2) and dust collection device (3), and adjusts the posture of the robot and truss to achieve all-round spraying of the segment mold.

2. The automatic, efficient, and uniform spraying device for segment molds according to claim 1, characterized in that: The nozzle (102) includes an outer nozzle tube (1021), a release agent conduit (1022), and a transverse conduit (1023). The two release agent conduits (1022) are inside the outer nozzle tube (1021), and the latter diameter is located inside the transverse conduit (1023), with their liquid outlets facing each other. The transverse conduit (1023) transversely penetrates the outer nozzle tube (1021).

3. The automatic, efficient, and uniform spraying device for segment molds according to claim 2, characterized in that: The nozzle (102) has a transverse spray head distributed radially along the brush body (101), with a spray coverage angle ≥270° and a nozzle orifice diameter of 0.5-1mm.

4. The automatic, efficient, and uniform spraying device for segment molds according to claim 1, characterized in that: The calibration needle of the vision device (2) is arranged in parallel with the camera. The camera is used to photograph the spraying state of the tube mold and to determine the position of the mold through visual calibration.

5. The automatic, efficient, and uniform spraying device for segment molds according to claim 1, characterized in that: The rotating platform (103) is driven by a motor to rotate the brush body (101) around its own axis at a speed of 20-50 r / min. The surface of the brush body (101) has a bristle density of ≥200 bristles / cm², so that the release agent is evenly coated on the surface of the tube mold.

6. The automatic, efficient, and uniform spraying device for segment molds according to claim 1, characterized in that: The compatible flange (4) is equipped with a standardized interface to adapt to gantry robots of different specifications, enabling rapid installation and attitude adjustment of the device.

7. An automatic, efficient, and uniform spraying device for segment molds according to claim 1, characterized in that: The negative pressure fan of the dust collection device (3) has an air volume of ≥1500m³ / h.

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