CN-121992327-A - Intelligent cooperative control system of automatic hot galvanizing equipment based on Internet of things

CN121992327ACN 121992327 ACN121992327 ACN 121992327ACN-121992327-A

Abstract

The invention relates to the technical field of intelligent control of hot galvanizing, in particular to an intelligent cooperative control system of automatic hot galvanizing equipment based on the Internet of things, which is used for determining the type of a workpiece to be galvanized and the position of an exhaust hole according to a design drawing so as to determine whether the workpiece has a missing plating risk and the time of hot galvanizing, acquiring current relevant data of zinc plating according to the judgment result of the missing plating risk and adjusting the relevant data to a standard data range, cleaning zinc ash on the surface of a zinc pot according to images of the surface of the zinc pot, determining a plating abnormal area according to each zinc plating image so as to determine whether missing plating phenomenon exists, determining the missing plating type according to readings of a thickness gauge of each plating abnormal area, and determining a galvanization adjustment strategy according to the missing plating type.

Inventors

XIE YONGSHENG
LI WEIXIANG
WANG MENG

Assignees

天津尚源金属表面处理有限公司

Dates

Publication Date: 20260508
Application Date: 20260302

Claims (10)

1. Automatic hot galvanizing equipment intelligence cooperative control system based on thing networking, its characterized in that includes: The data perception module is used for obtaining a design drawing of a workpiece to be galvanized and obtaining galvanization related data of hot galvanizing equipment; wherein, the relevant galvanization data comprise plating assisting liquid concentration, plating assisting liquid pH value and zinc liquid temperature; the image acquisition module is used for acquiring a galvanized image of a preset area of a workpiece to be galvanized and an image of the surface of the zinc pot; a portable thickness gauge for detecting abnormal areas of each plating layer; The intelligent processor is connected with the data sensing module and is used for determining the type of the workpiece to be galvanized and the position of the exhaust hole according to the design drawing so as to determine whether the pipe workpiece has a plating leakage risk and the plating time; A cooperative control module, comprising: The intelligent controller is respectively connected with the data sensing module, the image acquisition module and the intelligent processor and is used for acquiring current galvanization related data according to the judgment result of the existence of the risk of missing galvanization, adjusting the current galvanization related data to a standard data range and cleaning zinc ash on the surface of the zinc pot according to the surface image of the zinc pot; The intelligent analyzer is respectively connected with the image acquisition module and the portable thickness gauge and is used for determining a plating abnormal region according to each galvanization image so as to determine whether a plating leakage phenomenon exists, determining a plating leakage type according to the thickness gauge reading of each plating abnormal region, and determining a galvanization adjustment strategy according to the plating leakage type, wherein the intelligent analyzer comprises the steps of optimizing a pretreatment process of a workpiece to be galvanized and adjusting air knife parameters; Wherein the type of plating leakage includes true plating leakage and false plating leakage.
2. The intelligent cooperative control system of the automatic hot galvanizing equipment based on the internet of things according to claim 1, wherein the intelligent processor determines the type of the workpiece and the number of the exhaust holes according to a design drawing of the workpiece to be galvanized, determines that the plating omission risk exists according to a judgment result that the type of the workpiece is a tubular workpiece, and determines the plating missing time according to the thickness of the tube wall of the workpiece.
3. The intelligent cooperative control system of automated hot galvanizing equipment based on the internet of things according to claim 1, wherein the intelligent controller obtains current galvanization related data according to a judgment result based on the existence of a missing galvanization risk, compares the current galvanization related data with a corresponding standard data range, determines an adjustment parameter and adjusts the adjustment parameter to a standard data value, and comprises the following steps: determining the current galvanization related data in the corresponding standard data range as non-adjustment parameters; determining the current galvanization related data which are not in the corresponding standard data range as adjustment parameters and adjusting the adjustment parameters to corresponding standard data values; Wherein the standard data value is the middle value of the standard data range.
4. The intelligent cooperative control system of the automatic hot galvanizing equipment based on the internet of things according to claim 1, wherein the intelligent controller determines the surface zinc ash thickness according to the zinc pot surface image and cleans the zinc pot when the surface zinc ash thickness is larger than a preset thickness.
5. The intelligent cooperative control system of the automatic hot galvanizing equipment based on the internet of things according to claim 1, wherein the image acquisition module acquires a galvanizing image of a preset area of a workpiece to be galvanized, the galvanizing image of the preset area comprises a pipe opening edge image, a pipeline inner wall image and a welding seam surface image, the intelligent analyzer receives the galvanizing image of the preset area, performs image analysis on the galvanizing image of the preset area to determine a coating abnormal area, and determines that a coating missing phenomenon exists according to the existence of the coating abnormal area.
6. The intelligent cooperative control system of automated hot galvanizing equipment based on the internet of things according to claim 5, wherein the intelligent analyzer controls the portable thickness gauge to detect thickness in each abnormal plating area according to the judging result of the existence of the plating omission phenomenon, and determines the plating omission type of the corresponding abnormal plating omission area according to the reading of the thickness gauge, and the intelligent cooperative control system comprises: determining that the plating leakage type corresponding to the plating leakage abnormal area is false plating leakage based on the result that the reading of the thickness gauge is larger than or equal to the preset reading; And determining that the plating omission type corresponding to the plating omission abnormal region is true plating omission based on the result that the reading of the thickness gauge is smaller than the preset reading.
7. The intelligent cooperative control system of automated hot galvanizing equipment based on the internet of things according to claim 1, wherein the intelligent analyzer determines a galvanization adjustment strategy according to the type of missing galvanization, comprising: responding to the false plating leakage, and adjusting air knife parameters by the intelligent analyzer according to the reading of the thickness meter and the position of the plating leakage abnormal area; In response to true miss plating, the intelligent analyzer optimizes a pretreatment process of the workpiece to be galvanized.
8. The intelligent cooperative control system of automated hot galvanizing equipment based on internet of things according to claim 7, wherein the intelligent analyzer adjusts air knife parameters according to thickness meter readings and positions of missed plating abnormal areas, comprising: determining the position deviation of the purging angle to the surface of the principle workpiece according to the judging result that the position of the plating omission abnormal region is positioned at the edge of the pipe orifice; And determining to reduce the purge pressure according to the judgment result that the thickness meter reading is smaller than the reference reading.
9. The internet of things-based intelligent cooperative control system of automated hot dip galvanizing equipment according to claim 5, wherein the intelligent analyzer performs the following operations for image analysis process, comprising: Converting the galvanized image into a gray scale image, denoising, enhancing contrast and unifying the image resolution of each galvanized gray scale image; filling holes based on a preset gray threshold segmentation algorithm and a morphological closing operation of texture feature analysis to determine abnormal areas of a plating layer; Extracting the outline of the abnormal region by adopting a Canny edge detection algorithm, recording pixel coordinates, and converting the pixel coordinates into actual physical coordinates by combining a preset image scale And matching the actual physical coordinates with a three-dimensional model of a workpiece preset area, and marking the offset of the abnormal area relative to a workpiece datum point so as to generate accurate positioning of the abnormal area of the plating layer.
10. The internet of things-based intelligent coordinated control system of automated hot dip galvanizing equipment according to claim 9, wherein the intelligent analyzer performs the following operations to determine a plating anomaly region, comprising: screening candidate areas with gray values lower than a preset gray value based on a preset gray threshold segmentation algorithm; Performing texture feature analysis on each candidate region to determine an abnormal region with texture entropy larger than a preset texture entropy; Filling the cavity of each abnormal region by adopting morphological closing operation so as to determine the abnormal region of the plating layer.

Description

Intelligent cooperative control system of automatic hot galvanizing equipment based on Internet of things Technical Field The invention relates to the technical field of intelligent control of hot galvanizing, in particular to an intelligent cooperative control system of automatic hot galvanizing equipment based on the Internet of things. Background Hot dip galvanization is a common method for metal rust prevention, and the principle is that a pretreated steel member is immersed into molten zinc liquid, and a continuous compact zinc coating is formed through iron-zinc reaction, so that the corrosion resistance is improved. However, the phenomenon of miss-plating is a common and difficult to completely avoid defect in the hot dip galvanization process, and is mainly represented by the appearance of bare spots or blocky areas of the steel substrate on the surface of the coating. The generation of the missed plating is closely related to the multi-loop process control, namely, the continuity of the plating layer can be damaged if the residual oxide skin is caused by incomplete acid washing in the pretreatment stage, the surface oxidation is caused by improper plating assistant components or concentration, the formation of the iron-zinc alloy layer is hindered by the deviation of the temperature or the component control of the zinc liquid, rust returning or zinc ash is not cleaned in time before the work piece is dip-plated, and the like. Such defects not only reduce the anti-corrosion effect, but also increase the reworking cost, affecting the market competitiveness of the product. The application number 202410602095.8 discloses a band steel continuous hot galvanizing air knife process parameter setting method based on data driving, which comprises the steps of classifying according to the coating type, the coating thickness specification, the baseplate mark, the thickness and the width of the band steel, establishing an air knife parameter formula, calculating an air knife parameter formula data initial value by utilizing production process historical data, optimizing the air knife parameter formula data on line by utilizing production process data, calculating air knife pressure compensation by utilizing the air knife parameter formula according to actual coating thickness deviation, realizing air knife pressure setting on line correction, adopting the band steel continuous hot galvanizing air knife process parameter setting method based on data driving to replace manual experience setting, realizing manual experience extraction, storage and optimization, ensuring production process consistency and stability, effectively preventing quality defects such as zinc flow ripple, air knife trace and edge thickening by reasonably setting the air knife process parameters, being beneficial to further improving the coating thickness quality and control precision, and having good application and popularization prospects. It follows that the prior art has the following problems: The method does not judge whether the workpiece to be galvanized is easy to generate the plating leakage phenomenon or not, and accordingly, relevant parameter adjustment before galvanization is carried out, and the plating leakage detection and judgment are not carried out on the galvanized workpiece after galvanization is finished, so that the subsequent galvanization process still has the plating leakage phenomenon. Disclosure of Invention Therefore, the invention provides an intelligent cooperative control system of automatic hot galvanizing equipment based on the Internet of things, which is used for solving the problems that in the prior art, whether a workpiece to be galvanized is easy to generate a plating omission phenomenon is not judged, relevant parameters before galvanization are adjusted accordingly, and the plating omission detection and judgment are not carried out on galvanized parts after galvanization is finished, so that the plating omission phenomenon still exists in the follow-up galvanization process. In order to achieve the above purpose, the invention provides an intelligent cooperative control system of an automatic hot galvanizing device based on the Internet of things, comprising: The data perception module is used for obtaining a design drawing of a workpiece to be galvanized and obtaining galvanization related data of hot galvanizing equipment; wherein, the relevant galvanization data comprise plating assisting liquid concentration, plating assisting liquid pH value and zinc liquid temperature; the image acquisition module is used for acquiring a galvanized image of a preset area of a workpiece to be galvanized and an image of the surface of the zinc pot; a portable thickness gauge for detecting abnormal areas of each plating layer; The intelligent processor is connected with the data sensing module and is used for determining the type of the workpiece to be galvanized and the position of the exhaust hole according t