Research And Design Of High Altitude Spray Painting Monitoring System Based On FPGA

In recent years,with the rapid development of our country’s industry,metal building materials are widely used.In order to protect metal building materials from corrosion,it is necessary to spray paint the metal building materials,but spray painting the high-altitude metal building materials is more difficult.Traditional high-altitude painting jobs use manual spraying.Manual spraying requires scaffolding,long working cycle,slow spraying efficiency,spraying effect depends on the worker’s proficiency and paint will affect the worker’s health.Although the use of spraying robots can solve these problems,but after studying the current situation of spraying robots at home and abroad,it is found that most spraying robots are difficult to realize mobile spraying,unable to perform high-altitude spraying operations.In view of the above problems,this paper designed a set of high-altitude spraying system,the design of the research work includes:(1)According to the actual needs of the overall analysis,the system is divided into mobile module,painting module and visual module,and the three modules are discussed in detail.Firstly,the function and selection of mobile module are introduced.By comparing the current mainstream wall-climbing robots,the magnetic suction crawler wall-climbing robot is selected.Secondly,the function and composition of spraying module are introduced.Considering that the load-bearing capacity of the wall-climbing robot and the working environment are simple and relatively flat,the single degree of freedom manipulator is used as the carrier of the spray gun.Meanwhile,in order to ensure the consistency of paint film thickness each time,fuzzy PID algorithm is used to control the brushless DC motor.Finally,it introduces the function and composition of the visual module,and uses FPGA to process the data,so as to improve the real-time performance.(2)The drive circuit of the motor is designed with IR2110 chip;At the same time,FPGA is used to build a number of system hardware modules to realize the main algorithm in the system.The system hardware mainly includes the image acquisition module,image processing module and data interaction module.In order to improve the development efficiency,the Linux system is transplanted,and the fuzzy PID control and Ethernet transmission program are realized on it.Finally,two upper computers are written using QT to monitor the operation of the system.(3)The spraying area is determined by image processing,and the spraying trajectory and spraying effect are determined based on it.Image processing mainly includes preprocessing and processing part,the preprocessing part mainly uses histogram equalization and Gaussian filtering for image enhancement;The image processing part mainly realizes edge detection,image expansion and image projection based on improved Sobel operator,so as to locate the spraying area.At the same time,the motion of the spray gun is analyzed to determine the spraying trajectory.In order to reduce the spraying error,the double β distribution model was used to determine the best spraying spacing,so as to optimize the spraying trajectory.At the same time,histogram comparison method is used to distinguish spraying effect.(4)Carry out practical test on each module,connect each module after passing the test,and simulate the industrial field environment for normal spraying experiment and interference spraying experiment.The experimental test shows that the designed high-altitude spray painting system has good spraying effect and can monitor spraying operation in real time,achieving the desired effect.