A visual intelligent adjustment end-pressing plate control device

Abstract

The utility model discloses a kind of based on visual intelligent adjustment end pressing plate control device, to solve artificial adjustment low precision, poor efficiency, big security risk and other problems. System is constituted by core control component, execution adjustment component, visual acquisition component, security early warning component and power supply guarantee component. Core control component uses PLC controller or embedded processor, supports automatic / manual mode switching;Execution adjustment component contains multi-degree-of-freedom manipulator, and its clamping module is adapted to multi-specification nut;Visual acquisition component is through industrial camera and laser ranging sensor, accurately identifies bolt nut coordinate, defect and end pressing plate spacing and parallelism;Security early warning component responds fault in time through audible and visual alarm and remote notification;Power supply guarantee component ensures that core component continues to operate after power failure. The utility model is high in degree of automation, adapts to alkaline electrolytic cell harsh working condition, can guarantee sealing integrity and reaction stability, reduce equipment loss, improve operation convenience.

Description

Technical Field

[0001] This utility model relates to the field of electrolytic cell equipment technology, specifically to a vision-based intelligent adjustment end plate control device. Background Technology

[0002] Alkaline electrolyzers are core equipment in hydrogen production, chemical synthesis, and other fields, and the sealing performance of their end plates directly affects the efficiency of the electrolysis reaction and operational safety. Currently, the distance adjustment between the end plates of the electrolyzer mainly relies on manual operation, using tools such as wrenches to fine-tune the distance by turning the nuts on the bolts after the equipment is stopped and cooled. However, manual operation has many drawbacks: First, human error is relatively large, and uneven force application makes it difficult to accurately control the distance between the pressure plates, which can easily lead to inconsistent preload of the bolts, incomplete sealing of the electrolytic cell, and end plate misalignment, resulting in electrolyte leakage or gas leakage. Second, the operation efficiency is low, especially for electrolytic cells with multiple sets of bolts. Manual adjustment is time-consuming and labor-intensive, and the quality of operation is highly dependent on the experience of technicians, resulting in poor repeatability. Third, there is a lack of an effective distance monitoring mechanism, resulting in a delayed response and an inability to detect situations where the pressure plate distance exceeds the safe range in a timely manner. Maintenance is only carried out when there is obvious leakage or performance degradation, which affects the continuity and safety of production and may lead to equipment failure or even safety accidents. Fourth, during operation, the initial preload changes due to bolt stress relaxation and component thermal expansion and contraction, but manual intervention is not possible when the equipment is energized, pressurized, or operating at high temperatures, further increasing the probability of error and affecting the stability of the electrolytic reaction results.

[0003] Therefore, there is an urgent need for an intelligent system that can replace manual labor, provide precise adjustment, real-time monitoring, and alarm functions to address the shortcomings of existing technologies. Utility Model Content

[0004] The purpose of this invention is to overcome the defects in the existing technology and provide a vision-based intelligent adjustment end plate control device.

[0005] To achieve the above objectives, the technical solution of this utility model is as follows: A vision-based intelligent adjustment end plate control device, comprising: Visual acquisition component: It includes multiple visual modules, which are set above the gantry frame to acquire images and distance data related to the end pressure plate, and adjust the execution adjustment component based on the data as parameters; The adjustment assembly includes a multi-degree-of-freedom manipulator, the free end of which is equipped with a screwing mechanism corresponding to the pull rod nut on the electrolytic cell.

[0006] Furthermore, the vision module includes an industrial camera and a high-precision laser rangefinder; The industrial camera captures images of the end plate, bolts, and nuts, and generates the nut position coordinates. A high-precision laser rangefinder sensor detects the distance between the end plates on both sides of the electrolytic cell in real time. The vision modules are arranged circumferentially around the electrolytic cell, and the vision modules are arranged in pairs symmetrically on both sides of the electrolytic cell to monitor the parallelism of the end plates.

[0007] Furthermore, the free end of the manipulator of the adjustment assembly is provided with a mounting base plate, and the manipulator controls the lifting and rotation of the mounting base plate; the mounting base plate has a disc-shaped structure, and multiple radial adjustment parts are evenly distributed radially in the circumference of the mounting base plate. A screwing mechanism is provided on the free end of the outer side of the radial adjustment part, and the screwing mechanism cooperates with the cylinder nut.

[0008] Furthermore, the radial adjustment part includes a radial track and a telescopic part. The radial track is a track arranged radially along the mounting base. The telescopic part is provided with a sliding groove and is slidably connected to the radial track through the sliding groove. A screwing mechanism is provided at the end of the telescopic part away from the center.

[0009] Furthermore, the mounting base is provided with an electric telescopic structure for driving the telescopic part. The electric telescopic structure includes a ball screw, a drive motor, and a slider. The ball screw is rotatably arranged along a radial track. The output end of the drive motor is connected to the ball screw. The slider is arranged on the ball screw and is connected to the telescopic part.

[0010] Furthermore, the screwing mechanism includes a sleeve module, a drive module, and a transmission module. The drive module is fixedly installed at one end of the radial adjustment section near the center. The radial adjustment section is controlled to extend and retract radially. The sleeve module is installed on its outer free end. The sleeve module cooperates with the nut on the end pressure plate. The transmission module connects the drive module and the sleeve module along the radial adjustment section, and ensures that the drive module always drives the sleeve module to rotate when the radial adjustment section extends and retracts to different lengths.

[0011] Furthermore, the drive module includes a servo motor fixedly mounted at one end of the radial adjustment section near the center. The servo motor has drive sprockets at its dual output ends. The sleeve module is located at the end of the telescopic section. A screwing sleeve is rotatably mounted inside the sleeve housing. The screwing sleeve has a hexagonal through hole along its axial direction that matches the shape of the nut. The outer periphery of the screwing sleeve forms sprocket teeth. The servo motor drives the screwing sleeve to rotate through the transmission module.

[0012] Furthermore, the transmission module includes a chain sleeved around the outer periphery of the drive sprocket and the screwing sleeve. The transmission module also includes a first steering sprocket and a second steering sprocket. The first steering sprocket is rotatably located at the other end of the telescopic part away from the sleeve housing. The drive sprocket is located at the end of the radial track near the center. The second steering sprocket is located at the end of the radial track away from the center. The chain comes out from one side of the drive sprocket, then goes around the screwing sleeve, then around the first steering sprocket, then around the first steering sprocket and then around the second steering sprocket, so that the chain structure formed by the first steering sprocket and the second steering sprocket is formed, and then it goes back to the drive sprocket to form a closed loop.

[0013] Furthermore, the sleeve module is also equipped with a detachable anti-slip sleeve, and multiple sets of sleeve kits are inserted into the hexagonal through hole to change the size of the through hole; a torque sensor is also provided on the inner wall of the screw sleeve.

[0014] The advantages and beneficial effects of this utility model are as follows: 1. High degree of automation: Through the linkage of core control components and robotic arms, manual adjustment is completely replaced, and multiple bolts can be adjusted synchronously or sequentially, which greatly improves operating efficiency and reduces labor costs; 2. Precise adjustment accuracy: With the help of high-precision positioning, driving and monitoring technology, the spacing adjustment accuracy reaches ±0.01mm, and the parallelism of the end pressure plate can be calibrated in real time to ensure the integrity of the seal, avoid electrolyte or gas leakage, and ensure the stability of the electrolysis reaction results; 3. Comprehensive safety protection: It integrates multiple monitoring and alarm mechanisms for over-limit spacing, abnormal torque, component failure, bolt and nut defects, etc. It provides timely warnings through audible and visual alerts and remote notifications, and triggers shutdown protection to reduce the risk of equipment damage. 4. Strong adaptability: Supports replacement of multiple sensor types, adaptation of multiple nut specifications, automatic / manual mode switching and harsh environment protection, which can meet the installation and operation requirements of alkaline electrolytic cells of different specifications; 5. Convenient operation and maintenance: It has functions such as data recording and traceability, fault location and labeling, and quick component replacement, which facilitates equipment maintenance, fault diagnosis and operation status analysis, and improves operation and maintenance efficiency. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the usage status of a vision-intelligent adjustment end pressure plate control device according to this utility model; Figure 2 This is an exploded view of a vision-intelligent adjustment end plate control device according to this utility model; Figure 3 This is a schematic diagram of the installation structure of the visual acquisition component in this utility model; Figure 4This is a schematic diagram of the internal structure of the radial adjustment part in this utility model; Figure 5 This is a top view of the internal structure of the radial adjustment part in this utility model; In the diagram: 1. Electrolytic cell; 2. End pressure plate; 3. Twisting mechanism; 4. Robotic arm; 5. Mounting base; 6. Radial adjustment part; 7. Radial track; 8. Telescopic part; 9. Slide groove; 10. Ball screw; 11. Drive motor; 12. Slider; 13. Sleeve module; 14. Servo motor; 15. Drive sprocket; 16. Sleeve housing; 17. Upper through hole; 18. Lower through hole; 19. Twisting sleeve; 20. Hexagonal through hole; 21. Sprocket teeth; 22. Chain; 23. First steering sprocket; 24. Second steering sprocket; 25. Vision acquisition component; 26. Third steering sprocket. Detailed Implementation

[0016] The specific embodiments of this utility model will be further described below with reference to examples. These examples are only used to more clearly illustrate the technical solution of this utility model and should not be construed as limiting the scope of protection of this utility model.

[0017] A vision-based intelligent adjustment end plate control device is mainly used for the spacing adjustment and safety monitoring of the end plate 2 of an alkaline electrolyzer 1. It achieves automated, precise, and intelligent control of the spacing adjustment of the end plate 2 of the electrolyzer 1, comprehensively improving the operational stability and maintenance convenience of the alkaline electrolyzer 1. The following details the specific component selection, installation connection, workflow, and maintenance calibration. Figure 1-5 As shown, the specific embodiments of this utility model will be described in detail.

[0018] I. Component Selection and Parameter Setting (a) Core control components Core Control Components: As the central unit of the system, a Siemens S7-1500 series PLC controller is selected. This controller is equipped with a 16GB high-capacity storage unit and a high-speed computing chip, with a data processing latency of ≤5ms. It can quickly respond to feedback data from various sensors and output precise control commands. The storage unit pre-stores the standard distance threshold range of the pressure plate 2 (default setting is 10-30mm, which can be customized via an external touch screen), the adjustment logic program, the standard torque curve database, and calibration algorithms for different types of sensors. The standard torque curve database covers the tightening torque variation patterns of bolts of different specifications, providing data support for torque monitoring and fault diagnosis. The computing unit has functions such as threshold comparison, data fitting, curve comparison, and fault diagnosis. It can receive feedback data from the vision acquisition component 25, the torque detection unit, and the execution adjustment component in real time and process it efficiently. The command output unit outputs forward rotation, reverse rotation, stop, and other action commands or alarm triggering and cancellation commands to other components based on the calculation results. The mode switching unit supports free switching between automatic and manual modes to meet the adjustment needs of different scenarios. Meanwhile, the core control components have comprehensive data recording and traceability functions, which can automatically store data such as the time of each adjustment, initial distance, target distance, adjustment duration, peak torque, and whether an alarm occurs. The data storage time is ≥1 year and can be exported via USB interface or remote terminal, providing complete data support for equipment maintenance and fault tracing.

[0019] The torque detection unit is integrated into the core control component. Through data interaction with the torque sensor in the tightening mechanism 3, it detects the output torque of the robot arm 4 drive module in real time. The torque detection range is set to 10-500 N·m, with a detection accuracy of ≤±1%, enabling precise capture of torque changes during the adjustment process. The core control component has a built-in standard torque curve database that stores the torque change curves of bolts of different specifications during normal tightening. During adjustment, the actual torque curve is compared with the standard curve in real time. When the deviation rate is ≥15%, an alarm is immediately triggered and the adjustment operation is paused, facilitating the inspection of potential faults such as bolt jamming and thread damage.

[0020] (ii) Execution of adjustment components The adjustment assembly is a multi-degree-of-freedom industrial robot 4 that corresponds to the position of the bolts and nuts of the electrolytic cell 1. The free end of the robot 4 is fixedly equipped with a mounting base 5. The robot 4 can control the lifting, rotating, and moving actions of the mounting base 5. Multiple radial adjustment parts 6 are evenly distributed radially around the mounting base 5. The radial adjustment parts 6 can adopt an electric telescopic structure and be controlled to achieve radial telescopic adjustment. A screwing mechanism 3 is fixedly installed on its outer free end. The radial adjustment parts 6 can be adapted to the radius distance of the bolt distribution of different specifications of electrolytic cells 1 through telescopic adjustment.

[0021] Specifically, in this embodiment, there are twelve sets of tension bolts in the electrolytic cell 1, and four sets of tightening mechanisms 3 are provided on the mounting base 5. The four tightening mechanisms 3 are evenly distributed circumferentially and correspond to the four positions of the tension bolts. In actual use, these four sets of nuts can be tightened first, and then the robot arm 4 can be rotated at a certain angle to correspond to the next set of bolts. This cycle is repeated until all bolts are tightened. Of course, the tightening mechanisms 3 can also be set one-to-one according to the actual number of tension bolts. This embodiment takes the setting of four sets of tightening mechanisms 3 as an example. The mounting base 5 is provided with four sets of radial adjustment parts 6. The radial adjustment part 6 includes a radial rail 7 fixedly set on the mounting base 5 and a telescopic part 8 slidably connected to the radial rail 7. The telescopic part 8 is provided with a groove 9 corresponding to the radial rail 7. The mounting base 5 and the radial rail 7 are provided with a drive telescopic part 8 for... In practical use, the electric telescopic structure for telescopic adjustment can employ a linear motor to drive the movement of the telescopic part 8. Specifically, a ball screw 10 is rotatably connected within the radial track 7, with one end of the ball screw 10 connected to a drive motor 11. The drive motor 11 controls the rotation of the ball screw 10. A slider 12 is provided on the telescopic part 8, and the slider 12 is screwed to the ball screw 10. Thus, driven by the drive motor 11 and the ball screw 10, the slider 12 moves along the radial track 7, thereby pushing the telescopic part 8 to perform telescopic adjustment. Alternatively, a hydraulic cylinder can be used instead of a linear motor. In this way, when facing electrolytic cells 1 with different diameters, the radial track 7 can control the telescopic parts 8 to simultaneously align with the nuts to be tightened. The core control component controls the tightening mechanism 3, thereby simultaneously tightening multiple nuts. The tightening mechanism 3 consists of a sleeve module 13, a drive module, and a transmission module. The drive module is fixedly installed at one end of the radial adjustment section 6 near the center. It uses a high-precision servo motor 14 with a rated speed of 3000 rpm. Paired with a planetary gear reducer, the output torque amplification factor is proportional to the reduction ratio. It can adaptively adjust the output torque according to the bolt specifications and tightening requirements, effectively avoiding damage to small bolts due to overload. In this embodiment, a drive sprocket 15 is provided at the dual output end of the servo motor 14 of the drive module to transmit driving force. The sleeve module 13 is located at the end of the telescopic part 8, forming a circular sleeve housing 16 at one end of the telescopic part 8. The upper end face of the sleeve housing 16 has an upper through hole 17 for the pull rod to pass through, and the lower end face has a lower through hole 18 for the nut to pass through. The diameter of the upper through hole 17 is not less than the diameter of the pull rod, and the diameter of the lower through hole is not less than the outer diameter of the nut. This allows the sleeve housing 16 to be easily fitted onto the corresponding nut from top to bottom under the drive of the robot arm 4. Furthermore, a screwing sleeve 19 is rotatably provided inside the sleeve housing 16. The screwing sleeve 19 has a hexagonal through hole 20 along its axial direction that matches the shape of the nut, allowing it to be fitted onto the corresponding nut through the hexagonal through hole 20. Furthermore, the outer periphery of the screwing sleeve 19 forms a sprocket tooth portion 21. In actual use, by fitting a chain 22 around the outer periphery of the drive sprocket 15 and the screwing sleeve 19, the screwing of the nut can be controlled by the drive module through the sleeve module 13. In actual use, forward and reverse rotation control is possible. Of course, in this embodiment, in order to accommodate the extension and retraction control of the radial adjustment part 6, the transmission module is further improved. Specifically, the transmission module is also provided with a first steering sprocket 23 and a second steering sprocket 24. The first steering sprocket 23 is rotatably disposed at the other end of the extension and retraction part 8 away from the sleeve housing 16. The servo motor 14 and the drive sprocket 15 can be regarded as being disposed at the end of the radial track 7 near the center, while the second steering sprocket 24 is disposed at the end of the radial track 7 away from the center. The winding method of the chain 22 is as follows. Figure 5 As shown, the chain 22 extends from one side of the drive sprocket 15, then around the screwing sleeve 19, then around the first steering sprocket 23, and then around the second steering sprocket 24, forming an S-shaped chain structure through the first steering sprocket 23 and the second steering sprocket 24. It then loops back to the drive sprocket 15 to form a closed loop. In actual use, the screwing sleeve 19 and the first steering sprocket 23 move with the telescopic part 8. During the telescopic movement of the telescopic part 8, the S-shaped chain 22 can compensate for the movement of the chain 22 and maintain the good transmission function of the chain 22. Figure 5 As shown, in order to ensure that the chain does not interfere with its operation, a steering sprocket can be added, such as a third steering sprocket.

[0022] As another implementation, a universal drive shaft structure can be adopted, which can ensure that the power of the drive module is always stably transmitted to the sleeve module 13 when the radial adjustment part 6 is extended and retracted to different lengths, so as to achieve precise rotation of the sleeve module 13.

[0023] The sleeve module 13 also adopts a detachable anti-slip sleeve design and is equipped with three sets of sleeve kits of different sizes. Specifically, the sleeve kit is a kit set in the hexagonal through hole 20, thereby changing the size of the through hole and thus adapting to nuts of different specifications. At the same time, the inner wall of the screwing sleeve is equipped with a high-precision torque sensor with a measurement range of 0-200Nm, an accuracy of ±0.1%FS, and a response time of 1ms. It can provide real-time feedback of torque and rotation angle during the tightening of the nut, realizing precise force control operation. When the torque value exceeds the preset safety range, the core control component immediately outputs a stop command to the corresponding robot arm 4 and triggers the safety warning component to alarm, so as to avoid bolt stretching deformation or nut stripping.

[0024] (III) Visual Acquisition Component 25 The visual acquisition component 25 employs a combination of an industrial camera and a laser rangefinder sensor to ensure the comprehensiveness and accuracy of data acquisition related to the end platen 2. The industrial camera is an ultra-high-definition color camera with a resolution of 2592×1944 pixels, a frame rate of 14fps, and a lens focal length of 16mm. It is fixed to a gantry frame above the electrolytic cell 1 via a bracket, with an installation height of 11.5m above the end platen 2. It can clearly acquire image information of the edge of the end platen 2, bolt heads, and nuts, effectively identifying the wear degree and surface defects of the bolts and nuts. When a defect size ≥0.5mm or a wear amount ≥1mm is detected, the core control component immediately triggers a safety warning component to issue a yellow warning and accurately marks the location coordinates of the faulty bolts and nuts on the remote monitoring terminal, facilitating rapid location and handling by personnel.

[0025] The image processor employs an embedded AI processor, equipped with a deep learning-based object detection algorithm. It achieves a bolt and nut recognition accuracy of ≥99.5% and a coordinate extraction latency of ≤100ms, enabling rapid and accurate extraction of the spatial coordinates of bolts and nuts from acquired images, providing data support for the precise positioning of the robotic arm 4. The laser rangefinder is a high-precision model with a detection range of 5-50mm, an accuracy of ±0.01mm, and a detection frequency of 10Hz. Four to six sensors are configured to surround the electrolytic cell 1, symmetrically mounted on the upper part of the pressure plate 2 at the top of the electrolytic cell 1. The sensor's detection direction and path are unobstructed. Figure 3As shown, visual acquisition components 25 are symmetrically arranged on the upper part of the frame on both sides of the electrolytic cell 1. The dashed area represents the range of the visual acquisition components 25, and the line of sight within this range indicates the actual monitoring of the upper end pressure plates 2 of the electrolytic cell 1. It can be understood that when assembling or repairing the electrolytic cell 1, it needs to be placed vertically. The visual acquisition components 25 can conveniently detect the distance between the two end pressure plates 2. This symmetrical arrangement can not only detect the distance between the end pressure plates 2 on both sides of the electrolytic cell 1 in real time, but also monitor the parallelism (whether it is tilted). The detection data is transmitted to the core control component in real time in the form of digital signals. The core control component performs average processing on multiple sets of sensor data to improve the accuracy of distance detection. At the same time, it calculates the parallelism of the end pressure plates 2 by fitting multi-point data. When the parallelism deviation is ≥0.05mm / m, the corresponding robot arm 4 is automatically controlled to make compensation adjustments to ensure that the end pressure plates 2 are evenly attached.

[0026] (iv) Safety Early Warning Components The safety warning component consists of an audible and visual alarm module and a remote notification module, providing dual protection through local alerts and remote warnings. The audible and visual alarm module is fixedly installed on the top of the protective housing for easy observation and listening by staff. It includes a buzzer and a three-color LED warning light. The buzzer alarm volume is ≥85dB and supports three alarm tones: a low-frequency tone for distance over-limit alarms, a mid-frequency tone for torque abnormality alarms, and a high-frequency tone for equipment fault alarms. Different tones help staff quickly identify the alarm type. The three-color LED warning light can switch between red, yellow, and green. Green indicates normal system operation, yellow indicates the system is adjusting, and red indicates an over-limit alarm. The flashing frequency of the warning light can be adjusted according to the alarm level: 5Hz for a Level 1 alarm (serious fault), 2Hz for a Level 2 alarm (general fault), and 1Hz for a Level 3 alarm (minor warning). The combination of light status and flashing frequency visually presents the system's operating status and alarm level.

[0027] The remote notification module supports 4G / 5G network or industrial Ethernet communication and has 3-5 preset emergency contact numbers. When an alarm is triggered, it automatically sends warning information to the remote monitoring terminal, the preset contact's mobile phone SMS, and a dedicated APP. The warning information includes the over-limit distance value, abnormal torque data, fault location coordinates, timestamp, and on-site image information, ensuring that staff can obtain fault details in a timely manner and take quick countermeasures.

[0028] (v) Power supply protection components and protective housing The power supply protection component adopts a UPS (Uninterruptible Power Supply), which supports 220V / 380V adaptive input voltage and output voltage stability ≤±0.5%, providing a stable power supply for the system. When the external power supply is interrupted, the UPS can maintain the continuous operation of core components such as the core control component, visual acquisition component 25, and safety early warning component for ≥30 minutes, while sending a power outage early warning signal to the remote monitoring terminal to ensure that data is not lost during the adjustment process and that equipment is safe.

[0029] The system is equipped with a protective housing made of corrosion-resistant and high-temperature-resistant stainless steel, suitable for the corrosive environment of the alkaline electrolytic cell 1, preventing damage to internal components due to environmental factors and extending the system's service life. The housing surface features heat dissipation louvers and sealing strips, ensuring both heat dissipation for internal components and excellent sealing performance. An internal dehumidification module employs semiconductor condensation dehumidification technology to strictly control the relative humidity inside the housing within the range of 40%-60%, effectively preventing the influence of a humid environment on electronic components. Adjustable feet are located at the bottom of the protective housing, with a height adjustment range of 50-150mm, facilitating level calibration in different installation scenarios and ensuring uninterrupted movement of the robotic arm 4.

[0030] II. System Installation and Connection (a) Installation of protective casing The protective housing is fixed to a dedicated bracket on one side of the electrolytic cell 1. By adjusting the adjustable feet at the bottom, the protective housing is kept horizontal, while ensuring that the distance between the protective housing and the electrolytic cell 1 is reasonable to avoid affecting the movement range of the robotic arm 4. The core control components, power supply components, and moisture-proof and dehumidification modules are all installed inside the protective housing. The audible and visual alarm module of the safety warning component is fixed to the top of the housing, and the external touch screen is installed on the outside of the protective housing for easy on-site operation and parameter setting by the staff.

[0031] (ii) Installation of adjustment components According to the distribution of bolts in electrolytic cell 1, the multi-degree-of-freedom robot arm 4 is installed on the guide rails on both sides of the upper end of electrolytic cell 1. The installation height and angle of the robot arm 4 are adjusted so that the sleeve module 13 on the mounting base 5 can be accurately aligned with each bolt and nut. The guide rails are provided with sufficient adjustment stroke, which can be adapted and adjusted according to the size of electrolytic cells 1 of different specifications, ensuring that the robot arm 4 moves smoothly without jamming or interference during the adjustment process.

[0032] (III) Installation of visual acquisition component 25 A color industrial camera is fixed to a gantry frame above electrolytic cell 1 using a dedicated bracket. Adjusting the bracket height and camera angle ensures the camera lens clearly covers all bolts, nuts, and end pressure plates 2 of electrolytic cell 1, guaranteeing image integrity and clarity. Laser rangefinders are symmetrically installed at the edges and center of the upper end pressure plates 2 of electrolytic cell 1. The sensor's detection direction is perpendicular to the pressure plate plane, ensuring an unobstructed detection path. The sensors are connected to the core control components via shielded cables, effectively avoiding electromagnetic interference in the industrial environment and ensuring the stability of data transmission.

[0033] (iv) Electrical connection The core control components establish communication connections with the robotic arm 4, vision acquisition component 25, audible and visual alarm module, and power supply protection component via wired cables to achieve data interaction and command transmission. The remote notification module connects to an industrial Ethernet or 4G / 5G network to complete communication configuration with the remote monitoring terminal, ensuring timely push of early warning information. All cable connections use waterproof and corrosion-resistant connectors, and the wiring is neat, orderly, and securely fixed to adapt to the harsh environment of industrial sites.

[0034] III. System Workflow (a) Startup and parameter settings Upon powering on the power supply backup component, the system automatically enters a self-test process, comprehensively checking the connection status of each component, sensor accuracy, and power supply stability. If the self-test passes, the three-color LED warning light on the safety warning component will remain solid green, indicating that the system is operating normally. If a component malfunction or connection abnormality is detected during the self-test, the warning light will flash red, the buzzer will emit a high-frequency alarm tone, and the remote notification module will simultaneously send a fault warning message.

[0035] Operators can select the working mode (automatic or manual) via an external touchscreen: When selecting automatic mode, parameters such as the target distance of end pressure plate 2 and bolt specifications need to be input, and the system will automatically match the corresponding standard torque curve and adjustment logic; when selecting manual mode, no preset parameters are required, and operators can make manual adjustments via touchscreen or wireless operating handle.

[0036] (II) Automatic Mode Adjustment Procedure Visual Acquisition and Positioning: After system startup, the visual acquisition module initializes, and the industrial camera and laser rangefinder begin acquiring data. The image processor performs preprocessing such as denoising and enhancement on the images acquired by the industrial camera, and extracts the spatial coordinates of the bolts and nuts based on a deep learning algorithm; the laser rangefinder detects the distance data between the end plates 2 in real time, with a data sampling frequency of no less than 10Hz to ensure the real-time monitoring of the distance. The core control component receives the coordinate data output by the image processor and the distance data from the laser rangefinder, and, combined with the installation parameters of the electrolytic cell 1, determines the starting point for the operation of each bolt and nut.

[0037] Clamping and Fixing: The core control component sends motion commands to the robotic arm 4, which moves to the position of the first target bolt. The corresponding radial adjustment part 6 on the mounting base 5 extends radially, aligning the sleeve module 13 with the nut. The sleeve module 13 automatically switches to the appropriate sleeve kit according to the bolt specifications. Subsequently, the sleeve extends and securely clamps the nut. The pressure sensor detects the clamping force in real time and feeds it back to the core control component. The core control component adjusts the clamping force to a reasonable range of 10-30N to ensure secure clamping without damaging the nut.

[0038] Spacing Adjustment: The drive module operates according to segmented adjustment logic. First, it enters the rapid approach stage, driving the nut to rotate forward (when the spacing is too large) or reverse (when the spacing is too small) at a speed of 1mm / s, so that the spacing of the end pressure plate 2 quickly approaches the target value. When the spacing approaches the target value, the system automatically switches to the precise fine-tuning stage, and the adjustment speed is reduced to 0.1mm / s. The laser rangefinder provides real-time feedback on the spacing data of the end pressure plate 2. The calculation unit compares the actual spacing with the standard threshold and dynamically adjusts the rotation angle and speed of the robot arm 4 to ensure adjustment accuracy. When the actual spacing reaches the standard range, it enters the stabilization confirmation stage, maintaining the current clamping state for 30 seconds to ensure the sealing stability of the end pressure plate 2.

[0039] Torque monitoring and parallelism calibration: During adjustment, the torque detection unit monitors the output torque of the sleeve module 13 in real time, plots the actual torque curve, and compares it with the corresponding curve in the standard torque curve database. If the torque value exceeds the preset safety range, or the deviation rate between the actual torque curve and the standard curve is ≥15%, the core control component immediately outputs a stop command to the corresponding robot arm 4 and triggers the safety warning component to alarm. The buzzer emits a medium-frequency tone, the warning light flashes yellow (level two alarm), and fault information is recorded at the same time.

[0040] The core control component performs averaging and multi-point data fitting on the detection data from multiple laser rangefinders to calculate the parallelism of the end plate 2. When the parallelism deviation is ≥0.05mm / m, the robot arm 4 at the corresponding position is automatically controlled to perform compensation adjustment. By fine-tuning the tightness of the bolts and nuts at that position, the end plate 2 is ensured to fit evenly, avoiding tilting that could lead to poor sealing.

[0041] Cyclic Adjustment and Fault Handling: After the first bolt and nut are adjusted and meet the requirements, the sleeve module 13 loosens the nut, the radial adjustment part 6 retracts, and the mounting base 5 rotates at a preset angle, moving the sleeve module 13 to the position of the next set of bolts. The above clamping and adjustment process is repeated until all bolts and nuts are adjusted. If the spacing exceeds the standard range during the adjustment process and cannot be adjusted to the qualified range for 5 seconds, the core control component triggers the alarm module to start. The buzzer emits a low-frequency tone, and the warning light flashes red (Level 1 alarm). At the same time, the fault information is recorded and sent to the remote monitoring terminal.

[0042] (III) Manual Mode Adjustment Procedure The manual mode is suitable for precise fine-tuning needs in special scenarios. Operators can individually control the start, stop, forward rotation, and reverse rotation of any of the robotic arms 4 via an external touchscreen or wireless control handle. During adjustment, the distance data detected by the laser rangefinder and the torque data detected by the torque sensor are displayed in real-time on the touchscreen, allowing operators to easily monitor the adjustment process. If distance exceeds limits or torque becomes abnormal, the system will trigger an alarm mechanism, with a buzzer and warning light responding according to the corresponding alarm type, ensuring the safety and accuracy of the adjustment process.

[0043] (iv) Adjustment completion and data recording After all bolts are adjusted, the system automatically enters the spacing re-inspection process. The laser rangefinder sensor performs a comprehensive inspection of the spacing and parallelism of the end pressure plates 2 again. If the re-inspection is successful, the core control component generates a detailed work report, including the total adjustment time, the initial and final distances of each bolt, peak torque, and whether any alarms occurred. The work report can be exported and stored via USB interface or remote terminal. If the re-inspection fails, the system triggers an alarm, prompting personnel to troubleshoot the problem. Adjustment is then performed again after the fault is resolved.

[0044] IV. Maintenance and Calibration (a) Routine maintenance Regularly inspect the wear condition of the four sleeves of the robotic arm. If the wear-resistant rubber pads on the inner side of the sleeves are severely worn or the diamond-shaped anti-slip pattern is blurred, they should be replaced promptly. Replacement is simple and convenient, taking ≤5 minutes. Industrial camera lenses should be cleaned monthly using a dedicated lens cleaning cloth to wipe away dust and prevent dust from affecting image acquisition accuracy. The heat dissipation louvers on the protective housing surface should be cleaned regularly to ensure effective heat dissipation. The dehumidification module should be checked annually for condensate drainage to ensure proper dehumidification function and maintain the internal relative humidity within the range of 40%-60%.

[0045] (ii) Sensor calibration The laser rangefinder sensor undergoes accuracy calibration quarterly, using standard gauge blocks for comparative adjustment. Its core control component incorporates a calibration algorithm, automatically completing calibration after sensor type changes to ensure distance detection accuracy remains consistently within ±0.01mm. The industrial camera's image acquisition accuracy is calibrated every six months by photographing a standard calibration board and adjusting camera parameters to guarantee a bolt and nut recognition accuracy ≥99.5% and a coordinate extraction delay ≤100ms.

[0046] (III) Data Management and Power Supply Maintenance The adjustment data stored in the core control components should be exported and backed up regularly to facilitate long-term analysis of equipment operating status. A discharge test should be performed on the UPS annually to check if the backup power supply duration meets the requirement of ≥30 minutes. If the power supply duration does not meet the standard, the internal battery of the power supply should be replaced promptly to ensure that the core components of the system can operate normally and that data is not lost during a sudden power outage.

[0047] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A vision-based intelligent adjustment end plate control device, characterized in that, include Visual acquisition component: It includes multiple visual modules, which are set above the gantry frame to acquire images and distance data related to the end pressure plate, and adjust the execution adjustment component based on the data as parameters; The adjustment assembly includes a multi-degree-of-freedom manipulator, the free end of which is equipped with a screwing mechanism corresponding to the pull rod nut on the electrolytic cell.

2. The vision-based intelligent adjustment end plate control device according to claim 1, characterized in that, The vision module includes an industrial camera and a high-precision laser rangefinder. The industrial camera captures images of the end plate, bolts, and nuts, and generates the nut position coordinates. A high-precision laser rangefinder sensor detects the distance between the end plates on both sides of the electrolytic cell in real time. The vision modules are arranged circumferentially around the electrolytic cell, and the vision modules are arranged in pairs symmetrically on both sides of the electrolytic cell to monitor the parallelism of the end plates.

3. The vision-based intelligent adjustment end plate control device according to claim 1, characterized in that, The free end of the manipulator of the adjustment assembly is provided with a mounting base plate. The manipulator controls the lifting and rotation of the mounting base plate. The mounting base plate has a disc-shaped structure and multiple radial adjustment parts are evenly distributed radially around the circumference of the mounting base plate. A screwing mechanism is provided on the free end of the outer side of the radial adjustment part. The screwing mechanism cooperates with the cylinder nut.

4. The vision-based intelligent adjustment end plate control device according to claim 3, characterized in that, The radial adjustment part includes a radial track and a telescopic part. The radial track is a track arranged radially along the mounting base. The telescopic part is provided with a sliding groove and is slidably connected to the radial track through the sliding groove. A screwing mechanism is provided at the end of the telescopic part away from the center.

5. The vision-based intelligent adjustment end plate control device according to claim 4, characterized in that, The mounting base is equipped with an electric telescopic structure for driving the telescopic part. The electric telescopic structure includes a ball screw, a drive motor, and a slider. The ball screw is rotatably arranged along a radial track. The output end of the drive motor is connected to the ball screw. The slider is arranged on the ball screw and is connected to the telescopic part.

6. The vision-based intelligent adjustment end plate control device according to claim 3, characterized in that, The screwing mechanism includes a sleeve module, a drive module, and a transmission module. The drive module is fixedly installed at one end of the radial adjustment section near the center. The radial adjustment section is controlled to extend and retract radially. The sleeve module is installed on its outer free end. The sleeve module cooperates with the nut on the end pressure plate. The transmission module connects the drive module and the sleeve module along the radial adjustment section, and ensures that the drive module always drives the sleeve module to rotate when the radial adjustment section extends and retracts to different lengths.

7. The vision-based intelligent adjustment end plate control device according to claim 6, characterized in that, The drive module includes a servo motor fixedly mounted at one end of the radial adjustment section near the center. The servo motor has drive sprockets at its dual output ends. The sleeve module is located at the end of the telescopic section. A screwing sleeve is rotatably mounted inside the sleeve housing. The screwing sleeve has a hexagonal through hole along its axial direction that matches the shape of the nut. The outer periphery of the screwing sleeve forms sprocket teeth. The servo motor drives the screwing sleeve to rotate through the transmission module.

8. The vision-based intelligent adjustment end plate control device according to claim 7, characterized in that, The transmission module includes a chain sleeved around the outer periphery of the drive sprocket and the screwing sleeve. The transmission module also includes a first steering sprocket and a second steering sprocket. The first steering sprocket is rotatably located at the other end of the telescopic part away from the sleeve housing. The drive sprocket is located at the end of the radial track near the center. The second steering sprocket is located at the end of the radial track away from the center. The chain comes out from one side of the drive sprocket, then goes around the screwing sleeve, then around the first steering sprocket, then around the first steering sprocket and then around the second steering sprocket, so that the chain structure formed by the first steering sprocket and the second steering sprocket is formed, and then it goes back to the drive sprocket to form a closed loop.

9. The vision-based intelligent adjustment end plate control device according to claim 7, characterized in that, The sleeve module is also equipped with a detachable anti-slip sleeve. Multiple sets of sleeve kits are inserted into the hexagonal through hole to change the size of the through hole. A torque sensor is also provided on the inner wall of the screw sleeve.

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