CN110756359B - Automatic spraying device and method based on vision - Google Patents

Automatic spraying device and method based on vision Download PDF

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Publication number
CN110756359B
CN110756359B CN201911082429.9A CN201911082429A CN110756359B CN 110756359 B CN110756359 B CN 110756359B CN 201911082429 A CN201911082429 A CN 201911082429A CN 110756359 B CN110756359 B CN 110756359B
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spraying
long
workpiece
arm
robot
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CN110756359A (en
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李鑫
辛付豪
朱慧敏
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Hefei University of Technology
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Hefei University of Technology
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05BSPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/04Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
    • B05B13/0431Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with spray heads moved by robots or articulated arms, e.g. for applying liquid or other fluent material to 3D-surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05BSPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/08Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
    • B05B12/12Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to conditions of ambient medium or target, e.g. humidity, temperature position or movement of the target relative to the spray apparatus
    • B05B12/122Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to conditions of ambient medium or target, e.g. humidity, temperature position or movement of the target relative to the spray apparatus responsive to presence or shape of target
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05BSPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/0221Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work characterised by the means for moving or conveying the objects or other work, e.g. conveyor belts
    • B05B13/0228Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work characterised by the means for moving or conveying the objects or other work, e.g. conveyor belts the movement of the objects being rotative
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00Manipulators not otherwise provided for
    • B25J11/0075Manipulators for painting or coating

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  • Engineering & Computer Science (AREA)
  • Robotics (AREA)
  • Mechanical Engineering (AREA)
  • Spray Control Apparatus (AREA)
  • Manipulator (AREA)

Abstract

The invention discloses an automatic spraying device and method based on vision, wherein the device comprises the following components: the device comprises a plc controller, an integrated industrial personal computer, a long-arm spread spraying robot, conveying chains symmetrically arranged on two sides of the long-arm spread spraying robot, and a visual scanning device which spans over slide rails above the two conveying chains; and position sensors are respectively arranged at the scanning positions on the left side and the right side of the sliding rail and the spraying position of the conveying chain. The invention can realize the automatic spraying of the industrial robot to the workpiece in the working space under the complex industrial environment, thereby improving the working efficiency and saving the production cost.

Description

Automatic spraying device and method based on vision
Technical Field
The invention relates to the technical field of spraying devices for door panels, in particular to an automatic spraying device and method based on vision.
Background
Competition in the field of industrial spray production is becoming increasingly intense, and demands for automation level, optimization degree and quality are increasing. The introduction of the industrial robot spraying system is more environment-friendly, energy-saving, healthy and safe, and the cost is greatly reduced. The common spraying mode of the robot to the door panel generally comprises the following steps:
1. and placing the workpiece to be sprayed in a spraying area.
2. The spraying worker points to the spraying program of the teaching robot through the demonstrator.
3. If it is desired to spray the work pieces on both conveyor chains, manual teaching of the robot is also required.
The current common spraying mode of the robot is that a debugging person carries out point-to-point programming debugging according to the site of a workpiece to be sprayed. The method is complex and tedious in operation and long in time consumption, so that the spraying processing efficiency is low, the operator has high technical skill requirements, and meanwhile, the flexibility is poor; more importantly, if a set of teaching programs is rewritten after workpiece replacement, the automation application efficiency is low.
Disclosure of Invention
Aiming at the defects of machine spraying in an industrial environment, the invention provides an automatic spraying device and method based on visual identification, so that the automatic spraying of an industrial robot on a workpiece in a working space in a complex industrial environment can be realized, the working efficiency is improved, and the production cost is saved.
In order to achieve the aim of the invention, the invention adopts the following technical scheme:
the invention discloses an automatic spraying device based on vision, which is characterized by comprising the following components: the device comprises a plc controller, an integrated industrial personal computer, a long-arm spread spraying robot, conveying chains symmetrically arranged on two sides of the long-arm spread spraying robot, and a visual scanning device which spans over slide rails above the two conveying chains; position sensors are respectively arranged at the scanning positions on the left side and the right side of the sliding rail and the spraying position of the conveying chain;
if the visual scanning device reaches the scanning position of the position sensor on the sliding rail, the corresponding position sensor sends an in-place signal of the visual scanning device to the long-arm spraying robot;
the long-arm spreading spraying robot acquires the current position of the visual scanning device according to the in-place signal;
the plc controller starts a conveying chain below the current position of the visual scanning device according to the in-place signal, and sends a starting signal to the long-arm spread spraying robot;
the long-arm spraying robot turns to one side of the opened conveying chain from the middle cleaning position according to the starting signal, and simultaneously sends a starting scanning signal to the visual scanning device;
the visual scanning device receives the start scanning signal, starts scanning the workpiece above the conveying chain when the start scanning signal is at the rising edge, collects the geometric information of the surface of the workpiece and sends the geometric information to the integrated industrial personal computer;
the integrated industrial personal computer obtains a spraying track of the workpiece according to the geometric information of the surface of the workpiece and sends the spraying track to the long-arm spraying robot;
if the workpiece reaches the spraying position of the position sensor on the conveying chain, the corresponding position sensor sends an in-place signal of the workpiece to the long-arm spraying robot;
after the long-arm spreading spraying robot receives the in-place signal of the workpiece, spraying one surface of the workpiece on the conveying chain according to the spraying track, and sending a spraying completion signal to the plc controller after the spraying operation is completed;
the plc controller controls a motor shaft on the conveying chain to turn over the workpiece by 180 degrees according to the spraying completion signal, and sends the turning completion signal to the long-arm spread spraying robot;
the long-arm spread spraying robot performs spraying operation on the other surface of the workpiece according to the turning completion signal and the spraying track; and when the long-arm spraying robot completes the spraying operation again, the long-arm spraying robot automatically resets to the middle cleaning position.
The invention relates to an automatic spraying method based on visual identification, which is characterized by being applied to a spraying system consisting of a plc controller, an integrated industrial personal computer, a long-arm spread spraying robot, conveying chains symmetrically arranged at two sides of the long-arm spread spraying robot and visual scanning devices crossing slide rails above the two conveying chains, and comprising the following steps of:
step 1, respectively arranging position sensors at scanning positions on the left side and the right side of the sliding rail and at spraying positions of a conveying chain, and if the vision scanning device reaches the scanning position of the position sensor on the sliding rail, transmitting an in-place signal of the vision scanning device to the long-arm spraying robot by the corresponding position sensor;
step 2, the long-arm spread spraying robot acquires the current position of the visual scanning device according to the in-place signal;
step 3, the plc controller starts a conveying chain below the current position of the visual scanning device according to the in-place signal, and sends a starting signal to the long-arm spread spraying robot;
step 4, the long-arm spread spraying robot turns to one side of the opened conveying chain from the middle cleaning position according to the starting signal, and simultaneously sends a starting scanning signal to the visual scanning device;
step 5, the vision scanning device receives the start scanning signal, starts scanning the workpiece above the conveying chain when the start scanning signal is at the rising edge, collects the geometric information of the surface of the workpiece and sends the geometric information to the integrated industrial personal computer;
step 6, the integrated industrial personal computer obtains a spraying track of the workpiece according to the geometric information of the surface of the workpiece and sends the spraying track to the long-arm spraying robot;
step 7, if the workpiece reaches the spraying position of the position sensor on the conveying chain, the corresponding position sensor sends an in-place signal of the workpiece to the long-arm spraying robot;
step 8, after the long-arm spread spraying robot receives the in-place signal of the workpiece, spraying one surface of the workpiece on the conveying chain according to the spraying track, and sending a spraying completion signal to the plc controller after the spraying operation is completed;
step 9, the plc controller controls a motor shaft on the conveying chain to turn over the workpiece by 180 degrees according to the spraying completion signal, and sends the turning completion signal to the long-arm spread spraying robot;
step 10, the long-arm spread spraying robot performs spraying operation on the other surface of the workpiece according to the turning completion signal and the spraying track; and when the long-arm spraying robot completes the spraying operation again, the long-arm spraying robot automatically resets to the middle cleaning position.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the invention, an automatic spraying device is used, the workpiece is scanned through machine vision, the integrated industrial personal computer automatically generates a spraying program of the robot according to the geometric information of the workpiece surface collected by the scanning system, and the difficult problem that the spraying program of the industrial robot is complicated and complex is overcome, so that the spraying of a target object is realized with low cost, high speed and high precision.
2. According to the invention, through signal interaction between the industrial robot and the external plc, the spraying behavior between the industrial robot and the object to be sprayed is effectively controlled, and the tail end spray gun is ensured to be close to the target object and the execution logic step of the robot, so that the spraying can be effectively implemented.
3. According to the invention, a working mode of front and back rotation of the robot is adopted, and the externally controlled plc achieves the requirement of one robot for automatically spraying two conveying chains through controlling signals of the left conveying chain and the right conveying chain, so that the use efficiency of the robot can be effectively improved.
4. According to the invention, the device structure that the rotating motor is arranged on the conveying chain is adopted, the object to be sprayed is rotated 180 degrees through the rotating motor after the front surface is sprayed, and the robot can continue to spray the back surface of the workpiece, so that the requirements on the front surface and the back surface of the robot are met, and the working efficiency is greatly improved.
Drawings
FIG. 1 is a diagram showing the connection of the various parts of the present invention;
FIG. 2 is an external spatial distribution diagram of the present invention;
fig. 3 is a flow chart illustrating the operation of the present invention.
Detailed Description
In this embodiment, an automatic spraying device based on visual recognition, as shown in fig. 1 and 2, includes: the device comprises a plc controller, an integrated industrial personal computer, a long-arm spread spraying robot, conveying chains symmetrically arranged at two sides of the long-arm spread spraying robot, and a visual scanning device which spans over slide rails above the two conveying chains; position sensors are respectively arranged at the scanning positions on the left side and the right side of the sliding rail and the spraying position of the conveying chain;
if the visual scanning device reaches the scanning position of the position sensor on the sliding rail, the corresponding position sensor sends an in-place signal of the visual scanning device to the long-arm spraying robot; in the specific implementation, the visual scanning device adopts 6 labor-prone laser sensors to realize the scanning of the workpiece to be sprayed; the long-arm robot adopts a CMA GR-6160 six-axis robot;
the long-arm spreading spraying robot acquires the current position of the visual scanning device according to the in-place signal;
the plc controller starts a conveying chain below the current position of the visual scanning device according to the in-place signal, and sends a start starting signal to the long-arm spraying robot; the two conveying chains are mutually independent, the robot judges which conveying chain the workpiece is specifically positioned on according to the received signals, and the spraying of the workpiece is completed after the track is automatically generated; the two conveying chains can rotate 180 degrees at the spraying position so that the robot can finish spraying the front and back surfaces of the workpiece;
the long-arm spraying robot turns to a safety position at one side of the opened conveying chain from the middle cleaning position according to a starting signal to wait for a workpiece in-place signal, and simultaneously sends a starting scanning signal to the visual scanning device;
the visual scanning device receives a scanning starting signal, and when the scanning starting signal is at the rising edge, a switch of the scanning device is turned on to start data acquisition, and when the scanning device acquires the data of a workpiece, geometric information of the surface of the workpiece is transmitted to the integrated industrial personal computer in real time;
the integrated industrial personal computer obtains a spraying track of the workpiece according to the geometric information of the surface of the workpiece and sends the spraying track to the long-arm spraying robot;
if the workpiece reaches the spraying position of the position sensor on the conveying chain, the corresponding position sensor sends an in-place signal of the workpiece to the long-arm spraying robot;
after receiving the in-place signal of the workpiece, the long-arm spreading spraying robot performs spraying operation on one surface of the workpiece on the conveying chain according to the spraying track, and sends a spraying completion signal to the plc controller after the spraying operation is completed;
the plc controller controls a motor shaft on a conveying chain to turn over a workpiece by 180 degrees according to the spraying completion signal, and sends the turning completion signal to the long-arm spraying robot;
the long-arm spreading spraying robot performs spraying operation on the other surface of the workpiece according to the spraying track according to the overturning completion signal; and when the long-arm spraying robot completes the spraying operation again, the long-arm spraying robot automatically resets to the middle cleaning position.
In this embodiment, as shown in fig. 2 and 3, an automatic spraying method based on vision is applied to a spraying system composed of plc controllers, integrated industrial computers, long-arm spraying robots, conveying chains symmetrically arranged on two sides of the long-arm spraying robots, and vision scanning devices crossing over sliding rails above the two conveying chains, and is performed according to the following steps:
step 1, respectively arranging position sensors at scanning positions on the left side and the right side of a sliding rail and at spraying positions of a conveying chain, and if a visual scanning device reaches the scanning position of the position sensor on the sliding rail, transmitting an in-place signal of the visual scanning device to a long-arm spraying robot by the corresponding position sensor;
step 2, the long-arm spreading and spraying robot acquires the current position of the visual scanning device according to the in-place signal; if the robot receives the position signal of the scanning device reaching the scanning position above the left conveying chain and does not receive the position signal of the scanning device reaching the scanning position above the right conveying chain, the robot can judge that the scanning device is at the scanning position above the left conveying chain at the moment; if the robot receives the position signal of the scanning device reaching the scanning position above the left conveying chain and the position signal of the scanning device reaching the scanning position above the left conveying chain at the same time, the robot outputs an alarm of error scanning position; the operator is alerted to the condition of the signal of the inspection system.
Step 3, the plc controller starts a conveying chain below the current position of the visual scanning device according to the in-place signal, and sends a starting signal to the long-arm spraying robot;
step 4, the long-arm spraying robot turns to one side of the opened conveying chain from the middle cleaning position according to a starting signal, and simultaneously sends a starting scanning signal to the visual scanning device;
step 5, the vision scanning device receives a scanning starting signal, starts scanning a workpiece above the conveying chain when the scanning starting signal is at the rising edge, collects geometric information of the surface of the workpiece and sends the geometric information to the integrated industrial personal computer; after the visual scanning device is opened, the industrial personal computer refreshes data once every 4ms, in the workpiece scanning process, the integrated industrial personal computer processes the received geometric information of the surface of the workpiece in real time, the robot stops refreshing the acquired data after 10 seconds according to the speed of the conveying chain and the length of the workpiece, meanwhile, the visual scanning sensor is automatically closed, and the industrial personal computer generates a spraying program executed by the robot according to the received geometric data of the workpiece quickly after the scanning is finished.
Step 6, the integrated industrial personal computer obtains a spraying track of the workpiece according to the geometric information of the surface of the workpiece and sends the spraying track to the long-arm spraying robot; the visual scanning device scans the workpiece to be sprayed to obtain image data of the workpiece to be sprayed, the data are transmitted into the industrial personal computer for processing, and an image processing module for processing the image data of the workpiece to generate a geometric model and further processing the model and generating a path of robot spraying is integrated in the industrial personal computer; the image processing module processes the acquired data: the vision scanning module filters out the collected redundant image information after transmitting the acquired workpiece image data to the image processing module, optimizes the geometric information of the workpiece, and obtains a geometric model of the workpiece; the track generation module recognizes a geometric model of the workpiece processed by the image and calculates a spraying track of the robot to obtain a program code of spraying; the simulation and post-processing module is mainly used for realizing constant and smooth speed according to a spline algorithm; the robot control module performs kinematic calculation on the spline to form a final track of the robot; and finally, the integrated industrial personal computer sends the spraying program to the robot.
Step 7, when the workpiece reaches the spraying position of the position sensor on the conveying chain, the corresponding position sensor sends an in-place signal of the workpiece to the long-arm spraying robot;
step 8, after receiving the in-place signal of the workpiece, the long-arm spreading and spraying robot performs spraying operation on one surface of the workpiece on the conveying chain according to the spraying track, and sends a spraying completion signal to the plc controller after the spraying operation is completed;
step 9, the plc controller controls a motor shaft on a conveying chain to turn over a workpiece by 180 degrees according to the spraying completion signal, and sends the turning completion signal to the long-arm spraying robot;
step 10, the long-arm spreading spraying robot performs spraying operation on the other surface of the workpiece according to a spraying track according to a turnover completion signal; and when the long-arm spraying robot completes the spraying operation again, the long-arm spraying robot automatically resets to the middle cleaning position. After the robot finishes the spraying work on the front surface and the back surface of the workpiece, the robot outputs a spraying finishing signal to the external plc at first, and then the robot automatically returns to a cleaning position of the set robot to clean the spray gun. After receiving the spraying completion signal, the external plc controls the conveying chain to return, the sprayed plate is taken down, replaced by a new plate, and the spraying is continuously carried out according to the steps.
In conclusion, the automatic spraying system is more environment-friendly, energy-saving, healthy and safe, and the production cost is greatly reduced.

Claims (2)

1. An automatic spraying device based on vision, which is characterized by comprising: the device comprises a plc controller, an integrated industrial personal computer, a long-arm spread spraying robot, conveying chains symmetrically arranged on two sides of the long-arm spread spraying robot, and a visual scanning device which spans over slide rails above the two conveying chains; position sensors are respectively arranged at the scanning positions on the left side and the right side of the sliding rail and the spraying position of the conveying chain; the long-arm spreading spraying robot alternately moves left and right according to the visual scanning device to finish the spraying operation of workpieces on the conveying chains at two sides in turn;
if the visual scanning device reaches the scanning position of the position sensor on the sliding rail, the corresponding position sensor sends an in-place signal of the visual scanning device to the long-arm spraying robot;
the long-arm spreading spraying robot acquires the current position of the visual scanning device according to the in-place signal;
the plc controller starts a conveying chain below the current position of the visual scanning device according to the in-place signal, and sends a starting signal to the long-arm spread spraying robot;
the long-arm spraying robot turns to one side of the opened conveying chain from the middle cleaning position according to the starting signal, and simultaneously sends a starting scanning signal to the visual scanning device;
the visual scanning device receives the start scanning signal, starts scanning the workpiece above the conveying chain when the start scanning signal is at the rising edge, collects the geometric information of the surface of the workpiece and sends the geometric information to the integrated industrial personal computer;
the integrated industrial personal computer obtains a spraying track of the workpiece according to the geometric information of the surface of the workpiece and sends the spraying track to the long-arm spraying robot;
if the workpiece reaches the spraying position of the position sensor on the conveying chain, the corresponding position sensor sends an in-place signal of the workpiece to the long-arm spraying robot;
after the long-arm spreading spraying robot receives the in-place signal of the workpiece, spraying one surface of the workpiece on the conveying chain according to the spraying track, and sending a spraying completion signal to the plc controller after the spraying operation is completed;
the plc controller controls a motor shaft on the conveying chain to turn over the workpiece by 180 degrees according to the spraying completion signal, and sends the turning completion signal to the long-arm spread spraying robot;
the long-arm spread spraying robot performs spraying operation on the other surface of the workpiece according to the turning completion signal and the spraying track; and when the long-arm spraying robot completes the spraying operation again, the long-arm spraying robot automatically resets to the middle cleaning position.
2. The automatic spraying method based on visual identification is characterized by being applied to a spraying system consisting of a plc controller, an integrated industrial personal computer, a long-arm spread spraying robot, conveying chains symmetrically arranged on two sides of the long-arm spread spraying robot and visual scanning devices which transversely span a sliding rail above the two conveying chains, wherein the long-arm spread spraying robot alternately moves left and right according to the visual scanning devices to alternately finish the spraying operation of workpieces on the conveying chains on two sides; and is carried out according to the following steps:
step 1, respectively arranging position sensors at scanning positions on the left side and the right side of the sliding rail and at spraying positions of a conveying chain, and if the vision scanning device reaches the scanning position of the position sensor on the sliding rail, transmitting an in-place signal of the vision scanning device to the long-arm spraying robot by the corresponding position sensor;
step 2, the long-arm spread spraying robot acquires the current position of the visual scanning device according to the in-place signal;
step 3, the plc controller starts a conveying chain below the current position of the visual scanning device according to the in-place signal, and sends a starting signal to the long-arm spread spraying robot;
step 4, the long-arm spread spraying robot turns to one side of the opened conveying chain from the middle cleaning position according to the starting signal, and simultaneously sends a starting scanning signal to the visual scanning device;
step 5, the vision scanning device receives the start scanning signal, starts scanning the workpiece above the conveying chain when the start scanning signal is at the rising edge, collects the geometric information of the surface of the workpiece and sends the geometric information to the integrated industrial personal computer;
step 6, the integrated industrial personal computer obtains a spraying track of the workpiece according to the geometric information of the surface of the workpiece and sends the spraying track to the long-arm spraying robot;
step 7, if the workpiece reaches the spraying position of the position sensor on the conveying chain, the corresponding position sensor sends an in-place signal of the workpiece to the long-arm spraying robot;
step 8, after the long-arm spread spraying robot receives the in-place signal of the workpiece, spraying one surface of the workpiece on the conveying chain according to the spraying track, and sending a spraying completion signal to the plc controller after the spraying operation is completed;
step 9, the plc controller controls a motor shaft on the conveying chain to turn over the workpiece by 180 degrees according to the spraying completion signal, and sends the turning completion signal to the long-arm spread spraying robot;
step 10, the long-arm spread spraying robot performs spraying operation on the other surface of the workpiece according to the turning completion signal and the spraying track; and when the long-arm spraying robot completes the spraying operation again, the long-arm spraying robot automatically resets to the middle cleaning position.
CN201911082429.9A 2019-11-07 2019-11-07 Automatic spraying device and method based on vision Active CN110756359B (en)

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