JP2014092371A - Coating inspection system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coating inspection system allowing a coating worker to accurately and rapidly grasping an inspection result of the coating work.SOLUTION: The coating inspection system for performing inspection on the coating condition of a coated section on a member to be coated is a system for performing inspection on the coating condition of the coated section on the member to be coated and includes an infrared thermograph for photographing a coating area coated at least with the coated section among the members to be coated; and a display section which is arranged at a position that a coating worker can view and displays the temperature distribution of the coated area obtained by the photographing with the infrared thermograph. The display section can display a dynamic image 17 continuously displaying aging of the temperature distribution of the coated area and a static image 18 at a prescribed time of the dynamic image 17.

Description

  The present invention relates to a coating inspection system, and more particularly to a coating inspection system for inspecting a coating operation based on a temperature distribution in a coating region.

  Various components that make up the body of an automobile are subjected to various coatings, sealers, waxes, etc., for the purpose of improving the design such as appearance and the functionality such as sealing and rust prevention. . Since these application states greatly affect the quality and performance of the member to be applied, an inspection of the application state is performed at the time of application or after application to determine the quality.

  Here, in the inspection of the coating operation, various inspection means such as a visual inspection by an operator and a method for judging the quality based on an image obtained by an imaging means such as a camera are actually adopted. Has reached. On the other hand, when applying rust-preventive wax to bag-like members such as hoods and door panels, since the wax is also applied to the inside of the bag-like member, the inside application state is also inspected. Need to be done. However, it is difficult to check the internal coating state by visual observation by an operator or an imaging means such as a normal camera. Therefore, for example, Patent Document 1 proposes a coating distribution inspection method using an infrared camera.

  This inspection method is a method for determining whether or not wax has been properly applied by imaging an application site of a vehicle body with an infrared camera and analyzing a thermal image obtained thereby. Specifically, a thermal image obtained by imaging is divided into pixel units, and whether or not the unit is an application region based on the magnitude of the temperature increase rate within a predetermined period for each divided unit pixel (or thermal By determining whether the region is a diffusion region, the range of the application distribution is specified. The series of processes is performed by a data processing apparatus that stores an analysis algorithm for performing the processes and can transmit thermal image data obtained by imaging with an infrared camera.

JP 2010-112806 A

  As described above, according to the inspection method described in Patent Document 1, the application region can be automatically specified by performing a certain process on the thermal image data obtained by imaging with the infrared camera. However, if this type of application work is performed on an area that is not visible to the operator (inside the bag-like member), there is a high possibility that an unpainted area will occur, and therefore, an unpainted area remains. In many cases, it is necessary to re-apply (re-apply) the region where the ink has occurred. In the inspection method described in Patent Document 1, a monitor for displaying a temperature distribution is provided in the data processing apparatus, but the arrangement position is not particularly described. A personal computer is used as a data processing device. In this way, when the configuration is not such that the inspection result can be directly checked by the coating operator, for example, when repainting is necessary, information necessary for the repainting (there is unpainted at that time) It is difficult for the coating operator to grasp the area) accurately and quickly.

  In view of the above circumstances, a problem to be solved by the present invention is to provide a coating inspection system in which a coating operator can accurately and quickly grasp a coating work inspection result.

  The solution to the above problem is achieved by the coating inspection system according to the present invention. In other words, this inspection system is a system for inspecting the application state of the applied material to the member to be coated, and an infrared thermograph for imaging at least the coating region of the member to be coated, and visible to the coating worker. And a display unit that displays a temperature distribution of the application region acquired by imaging an infrared thermograph, and the display unit continuously displays a change over time of the temperature distribution of the application region. And a still image of a dynamic image at a predetermined time can be displayed.

  As described above, in the present invention, since the display unit for displaying the temperature distribution of the application region acquired by imaging of the infrared thermograph is arranged in a range that can be visually recognized by the application operator, the application operator himself indicates the application state. It is possible to confirm and perform an inspection regarding the quality of the application work. Further, at this time, the display unit can display a dynamic image that continuously displays the change over time in the temperature distribution of the application region, so that the application operator can watch the temperature distribution of the application target member while working. Application work can be performed. Therefore, the coating operation can be performed smoothly. Further, in the present invention, since the still image at a predetermined time of the dynamic image can be displayed on the display unit, for example, the still image at the end of the application work, that is, the temperature distribution of the application region immediately after the application work is completed. It can be confirmed in a stationary state. If the temperature distribution is in a static state, it can be checked in more detail and more accurately than when judging the quality of the application state by looking at a dynamic image whose state changes from moment to moment. In addition to being able to make a quick and accurate determination, the application operator can quickly and accurately grasp the area that needs to be repainted. Of course, it is possible to check in detail whether or not repainting is good by displaying a new still image at the end of each repainting operation. Therefore, not only the initial coating operation but also the repainting inspection can be performed quickly and accurately.

  In the coating inspection system according to the present invention, the display unit may display a dynamic image and a still image at the same time.

  As described above, the dynamic image and the still image regarding the temperature distribution of the application region can be displayed on the one display unit at the same time, and after the still image at a certain time of the dynamic image is displayed on the display unit, The temporal change of the temperature distribution after the acquisition of the still image is continuously displayed as a dynamic image. Thus, for example, after the necessity of repainting is performed based on the still image, the coating operation can be performed while comparing the still image with the dynamic image reflecting the intermediate result of the subsequent repainting operation. Therefore, it is possible to perform the coating operation while confirming in real time the region that has already been repainted and the region that still needs repainting, and the repainting operation can be performed smoothly and quickly.

  The application inspection system according to the present invention further includes a display instruction unit for instructing display of a still image on the display unit by an operation, and a conveyance instruction unit for instructing conveyance of a member to be coated by a conveying unit by the operation. It may be.

  By configuring in this way, the temperature distribution after the completion of the coating operation is displayed as a still image on the display unit by operating the display instruction unit after the coating operator has finished the coating operation. Then, when the application worker himself / herself determines the quality of the application operation and determines that there is no problem (no unpainted residue), by operating the conveyance instruction unit, for example, the application target member supported by a conveyor or the like is It can be transported toward the process. On the other hand, if the application operator determines that there is a problem (there is an unpainted area) as a result of determining whether the application operation is good or not using a still image, the application operation can be performed without operating the conveyance instruction unit. Therefore, based on the judgment of the coating operator, the coated member can be transported when there is no remaining coating and it can be transported to the next process. Can be done quickly and reliably.

  When the coating inspection system according to the present invention includes the display instruction unit and the conveyance instruction unit, the operation of the conveyance instruction unit is performed only after the still image is displayed on the display unit by the operation of the display instruction unit. It may be controlled to be effective.

  As described above, when repainting is considered, it is effective to arrange the above-described configuration (display instruction unit and conveyance instruction unit) within the reach of the operator's hands, but in that case, There is a concern about mis-conveying due to a pressing error. In this regard, for example, by controlling the display instruction unit and the conveyance instruction unit as described above, even if the display instruction unit and the conveyance instruction unit are mistakenly pressed, the coated member is not conveyed. . Therefore, it is possible to avoid the situation where the member to be applied flows to the next process without performing the coating inspection, and to perform the total inspection.

  As described above, according to the present invention, the inspection result of the application work can be accurately and quickly grasped by the application operator. Further, even when repainting is required, the repainting operation can be performed quickly and accurately.

It is a perspective view which shows the example of application of the application | coating inspection system which concerns on one Embodiment of this invention. It is sectional drawing of the bag structure part of the door containing an application | coating area | region. It is a front view which shows the structure of a display part, Comprising: It is a figure which respectively shows the display form of the display part at the time of (a) application | coating operation | work, (b) completion | finish of application | coating operation | work, and (c) completion | finish of application | coating inspection. It is a top view which shows the example of 1 structure of a display instruction | indication part and a conveyance instruction | indication part. It is a flowchart of the inspection method using the coating inspection system which concerns on one Embodiment of this invention.

  Hereinafter, a method for evaluating window reflection according to an embodiment of the present invention will be described with reference to FIGS.

  FIG. 1 is a perspective view showing an application example of an inspection system according to an embodiment of the present invention. As shown in the figure, this inspection system is an infrared thermograph 6 that individually images a side door 3, a back door 4, and a hood 5 to be applied to an application work station 2 of a vehicle body 1 as a member to be applied. And a monitor 7 as a display unit that is disposed at a position and orientation that can be visually recognized by the coating operator 8 and that displays the temperature distribution of the coating region acquired by imaging of the infrared thermograph 6. 7 can display the dynamic image 17 and the still image 18 (both refer to FIG. 3 described later) of the temperature distribution.

  In the present embodiment, using the above inspection system, a plurality of application workers 8 move in front of the side door 3, back door 4, and hood 5 to be applied, and the application gun 10 held in the hand. Then, the coating state when the rust-preventing wax is sprayed and applied toward the bag structure 11 of each member to be coated (side door 3, back door 4, hood 5) is inspected. Here, the details of the coating operation will be described by taking the side door 3 as an example. As shown in FIG. 2, the bag structure portion 11 of the side door 3 is, for example, an overlapping portion of the outer panel 12 and the inner panel 13. The outer panel 12 and the inner panel 13 are integrated by folding back (performing a hemming process) the outer peripheral portion of the outer panel 12 with the adhesive 14 filled. Then, the application worker 8 inserts the application gun 10 through a gap provided around the bag structure 11 and applies the inner surface of the outer panel 12 constituting the bag structure 11 and the inner surface of the inner panel 13. The wax 15 is applied as a coating.

  Further, in the present embodiment, as shown in FIG. 4, the inspection system includes a display instruction unit 20 for instructing display of the still image 18 on the monitor 7 by operation, and a conveying means 23 (see FIG. 1) by operation. Further, an operation member 22 provided with a conveyance instructing unit 21 for instructing conveyance of the vehicle body 1 is provided. In the present embodiment, since the above-described series of operations are performed while the vehicle body 1 is being conveyed, the conveyance is continued as long as there is a conveyance instruction. After the lapse, the vehicle body 1 is stopped. In the present embodiment, the operation of the conveyance instruction unit 21 is controlled to be effective only after the still image 18 is displayed on the monitor 7 by the operation of the display instruction unit 20. Thereby, when the display instruction | indication part 20 and the conveyance instruction | indication part 21 are pushed wrongly, it can avoid the situation where the vehicle body 1 flows into the following process, without receiving the application | coating inspection by the application | coating worker 8. FIG. The operation member 22 having the above-described configuration is attached to, for example, the application gun 10 and is in a state where the application operator 8 who uses the application gun 10 can immediately operate.

  FIG. 3 shows an example of the display form of the monitor 7 as a display unit. When only the dynamic image 17 is displayed (FIG. 3A), the dynamic image 17 and the still image 18 are displayed simultaneously. In some cases, the inspection result 19 is displayed (FIG. 3C). Here, the dynamic image 17 continuously displays the temporal change of the temperature distribution in the application region of the wax 15 obtained by imaging with the infrared thermograph 6, and the still image 18 is the dynamic image 17. The temperature distribution at a predetermined time is displayed.

  Further, the temperature distribution displayed as the dynamic image 17 or the still image 18 may be raw data obtained by imaging the target part (part including the application region of the wax 15) with the infrared thermograph 6. In order to make it easier to determine whether or not the wax 15 is appropriately applied from a more substantial viewpoint, the raw data may be subjected to a predetermined process.

  Specifically, for example, (1) the surface temperature of the member to be coated before applying the wax 15 and the application region of the wax 15 after starting to apply the wax 15 (refers to the region where the application is planned). The back surface temperature is acquired by imaging the member to be coated with the infrared thermograph 6 to calculate the actual temperature difference between the back surface temperature of the coating region and the surface temperature before coating, and coating by applying the wax 15. In consideration of the temperature rise of the area, set the allowable lower limit of the temperature difference between the back surface temperature of the application area and the surface temperature before application, and only the area where the actual temperature difference is equal to or greater than the allowable lower limit of the temperature difference. The dynamic image 17 and the still image 18 may be displayed on the monitor 7. In this case, the actual temperature difference reflects the latest back surface temperature distribution displayed on the dynamic image 17, and the still image 18 is displayed on the display instruction unit 20 for instructing the display of the still image 18. It reflects the backside temperature distribution at the time of operation.

  Alternatively, (2) the surface temperature of the member to be coated before applying the wax 15 and the application region of the wax 15 after starting to apply the wax 15 (similar to the above, the region where the application is planned) are indicated. The back surface temperature is acquired by imaging the member to be coated with the infrared thermograph 6 to calculate the actual temperature difference between the back surface temperature of the coating region and the surface temperature before coating, and the wax 15 for the member to be coated. Based on the application conditions, a theoretical formula indicating the relationship between the temperature difference between the back surface temperature of the application region and the surface temperature before application and the coating film thickness of the wax 15 is derived. By setting an allowable lower limit value of the temperature difference corresponding to the allowable lower limit value of the film thickness, only the area where the actual temperature difference is equal to or larger than the allowable lower limit value of the temperature difference is displayed on the monitor 7 as the dynamic image 17 and the still image 18. You may make it do. Also in this case, the actual temperature difference reflects the latest back surface temperature distribution displayed on the dynamic image 17, and the still image 18 displays the display instruction unit 20 that instructs the display of the still image 18. It reflects the backside temperature distribution at the time of operation.

  Next, an example of an inspection method using the coating inspection system having the above configuration will be described with reference to FIGS.

(S1) Application Work Process First, as shown in FIG. 2, when the vehicle body 1 is carried into a predetermined position (application work position) of the application work station 2, the side door 3, the back door 4, and the hood 5 are opened. In this state, a plurality of application workers 8 move in front of the side door 3, the back door 4, and the hood 5 that are the application targets, and each application member (side door 3) is held by an application gun 10 held in hand. Anti-rust wax 15 is sprayed and applied toward the bag structure 11 of the back door 4 and the hood 5). At this time, in the infrared thermograph 6 corresponding to each member to be coated, the coated region of the wax 15 is included in the imaging range among the outer surfaces of the side door 3, the back door 4, and the hood 5 on the outer side. In addition, imaging with the infrared thermograph 6 is performed, and thereby the temperature distribution in the application region is acquired. Then, the acquired temperature distribution in the application region of the wax 15 is displayed on the monitor 7 as a dynamic image 17 (see FIG. 3A). At this time, for example, the temperature distribution in the same region before application is acquired in advance, and the temperature distribution after the processing (1) or (2) is displayed on the monitor 7 as the dynamic image 17. You may do it.

(S2) Still Image Display Step When the application work of the wax 15 is completed, the application operator 8 operates the display instruction unit 20 of the operation member 22 to display the temperature on the monitor 7 as shown in FIG. A distribution still image 18 is displayed. In this case, the displayed still image 18 is a temperature distribution in the dynamic image 17 at the time when the display instruction unit 20 is operated. The display mode of the still image 18 at this time is not particularly limited. For example, as shown in the figure, the still image 18 and the dynamic image 17 may be simultaneously displayed in a state where they are arranged side by side. Further, the still image 18 may be displayed in a size larger than the dynamic image 17.

(S3) Pass / Fail Judgment Step In this way, when the temperature distribution of the application region is displayed on the monitor 7 as the still image 18, the application operator 8 who actually performed the application operation viewed the monitor 7 and displayed it on the monitor 7. Based on the still image 18, the quality of the application state is determined. That is, if the region showing the predetermined temperature (threshold value) or more in the temperature distribution displayed as the still image 18 includes all the regions where the application was planned, it is determined that the application state is good. Then, the process proceeds to the next (S4) vehicle body conveyance process. Alternatively, when the area indicating the threshold value or more does not include a part of the area where the application is planned, it is determined that the application state is poor, in other words, there is an unpainted area (S5) Proceed to the repair process (FIG. 5). As the display format on the monitor 7, for example, the color tone is clearly defined by a region showing a temperature above the threshold and a region showing a temperature below the threshold so that the application operator 8 can easily grasp at a glance. Different methods can be used.

(S4) Car body transporting step When the coating worker 8 determines that the coating state is good in the quality determination step, the coating worker 8 operates the transport instruction unit 21 of the operation member 22 to cause the transporting unit 23 to move the vehicle body. 1 is instructed. In the present embodiment, since the above-described series of operations is performed while the vehicle body 1 is being conveyed, the vehicle body 1 is continuously conveyed as it is if there is a conveyance instruction. Thus, for example, the vehicle body 1 that has been inspected is transferred to the next process by the transfer means 23, and a series of operations and inspections for the vehicle body are completed. The inspection result 19 is displayed on the monitor 7 by the operation of the conveyance instructing unit 21 (for example, “OK” is displayed), and it is confirmed that not only the eight coating workers but also the surrounding workers are in a good coating state. It can be recognized (FIG. 3C).

(S5) Re-painting step When the coating operator 8 determines that the coating state is poor in the above-described pass / fail determination step, that is, there is an unpainted portion, the coating worker 8 re-applies the wax 15 to the region where the unpainted portion remains. Do (repaint). In this case, after registering an area where there is an unpainted area in the still image 18 used for determination, the wax 15 is sprayed again with the tip (nozzle) of the application gun 10 directed to the corresponding position to apply the corresponding area. Do. At the same time, the wax 15 is applied to the unapplied area while confirming whether the dynamic image 17 has been properly repainted. When the repainting operation is completed in this manner, the display instruction unit 20 of the still image 18 is operated again, the temperature distribution at the end of the repainting operation is displayed again as the still image 18, the quality is determined, and the determination result is good The above steps (S2, S3, S5) are repeated until. The operation of the transport instruction unit 21 is not performed, and the vehicle body 1 stops when an allowable application work time has elapsed, and a warning sound or the like is generated. Further, the monitor 7 displays an inspection result 19 indicating that the coating is defective (for example, “NG” is displayed), and the surrounding workers including the eight coating workers can recognize that the coating is defective. .

  As described above, in the present invention, since the monitor 7 for displaying the temperature distribution of the application region acquired by the imaging of the infrared thermograph 6 is provided in the range that the application operator 8 can visually recognize, the application operator 8 itself The state of application can be confirmed and an inspection regarding the quality of the application operation can be performed. At this time, the monitor 7 can display a dynamic image 17 that continuously displays the change over time in the temperature distribution of the application region, so that the temperature distribution of the member to be applied can be displayed while the application operator 8 is working. The coating operation can be performed while watching. Therefore, the coating operation can be performed smoothly. Further, since the still image 18 at a predetermined time of the dynamic image 17 can be displayed on the monitor 7, for example, the still image 18 at the end of the application operation, that is, the temperature distribution of the application region immediately after the application operation is completed is in a static state. Can be confirmed. As a result, the quality of the application state can be checked in detail and accurately, so that it is possible to quickly and accurately determine the presence or absence of unpainted areas, and the application operator 8 himself can quickly and accurately also in areas where repainting is necessary. I can grasp it. Of course, it is possible to check the repaint quality in detail by newly displaying the still image 18 at the end of each repainting operation. Therefore, not only the initial coating operation but also the repainting inspection can be performed quickly and accurately.

  Further, in the present embodiment, the dynamic image 17 and the still image 18 regarding the temperature distribution in the application region are simultaneously displayed on one monitor 7 (FIGS. 3B and 3C). After the still image 18 at a certain time 17 is displayed on the monitor 7, the temporal change of the temperature distribution after the acquisition of the still image 18 is continuously displayed on the dynamic image 17. Thus, after the necessity of repainting is performed based on the still image 18 as described above, the coating operation is performed while comparing the still image 18 with the dynamic image 17 reflecting the intermediate result of the subsequent repainting operation. Can do. Therefore, it is possible to perform the coating operation while confirming in real time the region that has already been repainted and the region that still needs repainting, and the repainting operation can be performed smoothly and quickly.

  Further, in the present embodiment, a display instruction unit 20 that instructs the display of the still image 18 on the monitor 7 by operation and a conveyance instruction unit 21 that instructs the conveyance of the vehicle body 1 by the conveyance unit 23 by operation are further provided. Therefore, after the application operator 8 finishes the application operation, the temperature distribution after the application operation is completed is displayed on the monitor 7 as a still image 18 by operating the display instruction unit 20. Then, when the coating worker 8 himself / herself determines whether the coating operation is good or not and determines that there is no problem (there is no unpainted), the transport instruction unit 21 is operated to transport the vehicle body 1 having the member to be coated. 23 can be continued. On the other hand, if the application worker 8 determines that there is a problem (there is an unpainted area) as a result of determining whether the application operation is good or not using the still image 18, the operation until the predetermined time elapses unless the conveyance instruction unit 21 is operated. The repainting operation can be performed without stopping the vehicle body 1. In addition, it is possible to transport the corresponding vehicle body 1 without stopping by operating the transport instructing unit 21 when the coating operator 8 determines that the unpainted portion disappears and can be transported to the next process by the repainting operation. . As described above, it is possible to perform a series of these inspections and transport operations quickly and reliably with respect to the total number.

  In the present embodiment, the monitor 7 serving as a display unit is disposed above the vehicle body 1 flowing on the coating work station 2. As shown in FIG. 1, this type of coating operation is normally performed on the production line of the vehicle body 1 that is a member to be coated, and a plurality of coating workers 8 perform a plurality of sites of coating work simultaneously. Therefore, if the monitor 7 is disposed just to the side of the coating work station 2, the other workers including the coating worker 8 in other parts and the surrounding facilities block the field of view, so In some cases, the temperature distribution cannot be confirmed. In this respect, in the present embodiment, the monitor 7 is disposed above the vehicle body 1 and in the direction of the application worker 8 who is in charge of each application site, so this type of problem is avoided as much as possible. The visibility of the corresponding application worker 8 can be improved.

  As mentioned above, although one Embodiment of this invention was described, this invention can also take a structure other than the above, unless it deviates from the structure reflecting the intent.

  For example, in the above-described embodiment, the case where the operation member 22 provided with the display instruction unit 20 and the conveyance instruction unit 21 is mounted on the coating gun 10 is illustrated, but of course the present invention is not limited to this mode. For example, the display instruction unit 20 and the conveyance instruction unit 21 may be arranged within the reach of the application worker 8 during the application operation, such as equipment installed near the work area or the application operator 8 himself / herself. That's fine. Alternatively, the display instruction unit 20 and the conveyance instruction unit 21 may also be used as an injection switch (lever) of the application gun 10. In this case, the operation of turning off the injection switch after the application work is completed functions as a display trigger for the still image 18. The subsequent temperature operation of the injection switch functions as a display trigger for the dynamic image 17 or an imaging acquisition trigger for the infrared thermograph 6.

  In the above embodiment, the case where the application work is performed while the vehicle body 1 is being transported is taken as an example. Of course, the application work is performed with the vehicle body 1 introduced onto the application work station 2 temporarily stopped, As a result of the inspection (good / bad determination) by the coating worker 8 itself, it may be determined that there is no unpainted area, and the conveyance instruction unit 21 may be operated to control the conveyance of the vehicle body 1 to be resumed.

1 Car body 2 Application work station 3 Side door 4 Back door 5 Hood 6 Infrared thermograph 7 Monitor 8 Application worker 10 Application gun 11 Bag structure 12 Outer panel 13 Inner panel 14 Adhesive 15 Wax 17 Dynamic image 18 Still image 19 Inspection Result 20 Display instruction section 21 Transport instruction section 22 Operation member 23 Transport means

Claims (2)

A coating inspection system for inspecting a coating state of a coating material on a member to be coated,
An infrared thermograph that images at least a coating region to which the coating material is coated among the coated members;
A display unit that is disposed at a position where a coating operator can visually recognize the temperature distribution of the coating region acquired by imaging the infrared thermograph;
The display unit is a coating inspection system capable of displaying a dynamic image that continuously displays a temporal change in the temperature distribution of the coating region and a still image at a predetermined time of the dynamic image.   The coating inspection system according to claim 1, further comprising: a display instruction unit that instructs to display the still image on the display unit by an operation; and a conveyance instruction unit that instructs the conveyance of the member to be coated by a conveying unit by the operation. .

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