CN111744735B - Control method based on surface spraying simulation of artware - Google Patents

Control method based on surface spraying simulation of artware Download PDF

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CN111744735B
CN111744735B CN202010649029.8A CN202010649029A CN111744735B CN 111744735 B CN111744735 B CN 111744735B CN 202010649029 A CN202010649029 A CN 202010649029A CN 111744735 B CN111744735 B CN 111744735B
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spraying
handicraft
artware
spray
industrial camera
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CN111744735A (en
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何炳蔚
赖宁斌
何银生
兰天
陈永斌
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Fuzhou University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B05D1/04—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/08—Arrangements 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
    • B05B12/081—Arrangements 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 the weight of a reservoir or container for liquid or other fluent material; responsive to level or volume of liquid or other fluent material in a reservoir or container
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/08—Arrangements 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
    • B05B12/12—Arrangements 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
    • B05B12/122—Arrangements 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/06—Natural ornaments; Imitations thereof

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Abstract

The invention relates to a control method based on surface spraying simulation of an artwork, which comprises the following steps: step S1: simulating to obtain a simulation result of spraying the surface of the handicraft; step S2: determining the position of the missed spraying on the surface of the handicraft according to the spraying simulation result, and further carrying out image acquisition on the position of the missed spraying to obtain a real-time detection result of the spraying of the handicraft; step S3: automatically adjusting the control parameters of the spraying equipment according to the spraying simulation result and the real-time detection result of the spraying of the artware, replanning the spraying process of the artware and optimizing the spraying process of the artware; step S4: and storing the spraying simulation result of the step S1, the real-time detection result of the spraying of the artware of the step S2 and the control parameters of the spraying equipment of the step S3 into an artware surface spraying database. The invention can improve the spraying efficiency of the surface of the handicraft.

Description

Control method based on surface spraying simulation of artware
Technical Field
The invention relates to the technical field of industrial production design automatic control, in particular to a control method based on handicraft surface spraying simulation.
Background
In the field of spraying of artware, due to the special, complex and diversified product structure, different influences are often caused on the spraying effect, and the most common defect is that the artware is missed to spray. The diversified product structure of the handicraft makes the detection of the missing spraying defect area difficult, so that the simulation technology is widely applied to the field of spraying the handicraft.
At present, the known handicraft spraying simulation method is to establish a mathematical model of the thickness of a paint film on the surface of a product to obtain the thickness of the paint film at different positions on the surface of a handicraft with a regular shape, and the missing spraying points are mostly boundary points at the positions with larger surface curvature. However, the self-shielding blow-by situation generated by the handicraft structure cannot be obtained through such simulation, and the blow-by situation displayed by the two-dimensional picture is far less intuitive than the three-dimensional display.
The coating process of the traditional handicraft manufacturing enterprise mainly comprises sample polishing, sample coating and product detection, wherein the whole process of a small and medium-sized enterprise is difficult to realize full automation. Because the track system of the paint spraying equipment is closed and the surface of the handicraft has self-shielding condition, the handicraft inevitably has the problems of missing spraying and the like in the spraying process. Semi-automatic detection equipment is still used in the product detection process of many small and medium-sized enterprises, and a large amount of manual work is needed to identify whether the coated products are qualified or not. Because various problems of missing spraying exist objectively, simulation of the spraying process of the artware is a technical design problem in product manufacturing, and therefore, development of the visual inspection technical research of the spraying process of the surface of the artware has important significance for development of the manufacturing industry of the artware and small commodities in China.
Disclosure of Invention
In view of this, the present invention provides a control method based on surface spraying simulation of an artwork, which can improve the spraying efficiency of the surface of the artwork.
The invention is realized by adopting the following scheme: a control method based on spraying simulation of a handicraft surface specifically comprises the following steps:
step S1: simulating to obtain a simulation result of spraying the surface of the handicraft;
step S2: determining the position of the missed spraying on the surface of the handicraft according to the spraying simulation result, and further carrying out image acquisition on the position of the missed spraying to obtain a real-time detection result of the spraying of the handicraft;
step S3: automatically adjusting the control parameters of the spraying equipment according to the spraying simulation result and the real-time detection result of the spraying of the artware, replanning the spraying process of the artware and optimizing the spraying process of the artware;
step S4: and storing the spraying simulation result of the step S1, the real-time detection result of the spraying of the artware of the step S2 and the control parameters of the spraying equipment of the step S3 into an artware surface spraying database.
Further, the step S2 specifically includes the following steps:
step S21: adjusting the pose of the industrial camera according to the position information of the missed spray, wherein the pose comprises the vertical distance between the camera and the handicraft, the front-back distance and the horizontal angle of a camera lens;
step S22: adjusting the pose of the industrial camera according to the parameters calculated in the step S21, and further acquiring image information of the position of the missed spray;
step S23: and (5) carrying out contour extraction on the image of the missed spray position collected in the step S22 to obtain a real-time detection result of the spraying of the artware.
Further, step S21 is specifically: calculating the following parameters according to the central coordinates of each missing spraying area, the size of the handicraft, the focal length of the industrial camera lens and the size of the photosensitive sensor:
1) calculating the working distance D of the industrial camera:
Figure BDA0002574215030000031
in the formula, FL is the focal length of a lens of the industrial camera, FOV represents the view field of the industrial camera, and SH represents the size of the photosensitive sensor;
2) calculating the vertical distance h between the industrial camera and the center of the handicraft according to the center coordinates of the spray leakage area and the vertical height of the camera holder:
h＝|z-h0|；
wherein z represents the z-axis coordinate of the center of the missed spray region, h0Representing the vertical height of the camera pan-tilt;
3) calculating the horizontal angle theta of the industrial camera lens:
θ＝arcsin(h/D)；
the front-back distance between the industrial camera and the center of the handicraft article is as follows: d × cos θ.
Further, step S23 is specifically: and extracting the contours in the acquired images by adopting a K-Means clustering segmentation algorithm, and obtaining the size information of each contour through morphological processing.
Further, step S3 specifically includes the following steps:
step S31: determining the optimal parameters of the spraying equipment according to the spraying simulation result and the real-time detection result of the spraying of the artware and transmitting the parameter results to the control terminal;
step S32: the control terminal automatically adjusts relevant parameters of the spraying equipment, and the parameters comprise: paint spraying flow, vertical running speed of a spray head, rotating speed of a rotary table of the spray head and electrostatic voltage.
Further, in step S31, the determining the optimal parameters of the spraying device specifically includes:
1) optimizing the paint spraying flow V:
V＝V'+[N/3]ω；
in the formula, V' is the initial paint spraying flow, N is the average leaked paint spraying number of the surface of the handicraft, and omega is a paint spraying flow increasing parameter;
2) optimizing the vertical running speed v of the spray head passing through a leakage spray area:
ν＝ν'-10(S/S0)；
wherein v' is the initial vertical running speed, S0The surface area of the handicraft is shown, and S is the area of a leakage spraying area;
3) optimizing the rotating speed n of the nozzle rotating disc:
n＝n'+1000(1+9.2γ)；
in the formula, n' is the initial rotating speed, and gamma is the blow-by rate of the surface of the handicraft;
4) optimizing the electrostatic voltage U:
Figure BDA0002574215030000041
in the formula, U' is an initial electrostatic voltage.
Compared with the prior art, the invention has the following beneficial effects: according to the invention, the position of the missed spray on the surface of the handicraft is determined according to the obtained spraying simulation result, the image information is further acquired according to the position of the missed spray, the spraying procedure of the handicraft is re-planned, the accurate spraying on the surface of the handicraft is completed, and the flexibility and the automation degree of the spraying process are improved. And meanwhile, the spraying simulation software further controls the control parameters of the spraying equipment according to the simulation result and the real-time detection result of spraying the artware so as to realize the complete spraying of the surface of the artware. Finally, the spraying simulation software can automatically store the position information, the image information, the artware spraying procedure information, the control parameters of the spraying equipment and other information obtained from the simulation result into an artware surface spraying database, so that the database information can be quickly called in the future, the artware surface spraying efficiency is improved, the labor intensity of operating workers is reduced, and the life safety of the workers is protected. The control method based on the simulation of the spraying of the surface of the handicraft has universal applicability to most of industrial handicraft simulation spraying, has a wide market application range and has a wide market application prospect.
Drawings
Fig. 1 is a control software interface diagram according to an embodiment of the present invention.
FIG. 2 is a schematic flow chart of a method according to an embodiment of the present invention.
Detailed Description
The invention is further explained below with reference to the drawings and the embodiments.
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
As shown in fig. 2, the present embodiment provides a control method based on a craft surface spraying simulation, which specifically includes the following steps:
step S1: simulating to obtain a simulation result of spraying the surface of the handicraft; adopting point cloud-based handicraft surface spraying defect simulation software to simulate the handicraft surface spraying, wherein the software interface adopted in the embodiment is shown in figure 1 and comprises a simulation result display interface and a functional operation area, an operator firstly introduces a point cloud model of the handicraft, and then inputs a three-dimensional coordinate of a suspension reference point S and a front spraying direction vector to obtain a suspension attitude in the handicraft spraying process; starting clicking, calculating self-shielding areas in the front and back spraying process by software, and calculating the paint film thickness corresponding to each point in the non-self-shielding areas; finally displaying the spraying simulation result of the handicraft, wherein the dark color area is the area with self-shielding and the paint film thickness less than 25 mu m, and the light color area is the area with good spraying quality; wherein, the simulation result can be obtained by adopting the method in CN 201811346682.6;
step S2: determining the position of the missed spraying on the surface of the handicraft according to the spraying simulation result, and further carrying out image acquisition on the position of the missed spraying to obtain a real-time detection result of the spraying of the handicraft; the method specifically comprises the following steps:
step S21: adjusting the pose of the industrial camera according to the position information of the missed spray, wherein the pose comprises the vertical distance between the camera and the handicraft, the front-back distance and the horizontal angle of a camera lens;
step S22: adjusting the pose of the industrial camera according to the parameters calculated in the step S21, and further acquiring image information of the position of the missed spray;
step S23: and (5) carrying out contour extraction on the image of the missed spray position collected in the step S22 to obtain a real-time detection result of the spraying of the artware.
Wherein, step S21 specifically includes: the control terminal calls a camera pan-tilt control algorithm, inputs the center coordinates of each missed spray area, the size of the handicraft, the focal length of a lens and the size of a sensor, and calculates the following parameters:
1) calculating the working distance D of the industrial camera:
Figure BDA0002574215030000071
wherein FL is the focal length of the industrial camera lens, FOV represents the field of view of the industrial camera (i.e. the maximum value of the field of view in the vertical and horizontal directions), and SH represents the size of the photosensitive sensor;
2) calculating the vertical distance h between the industrial camera and the center of the handicraft according to the center coordinates of the spray leakage area and the vertical height of the camera holder:
h＝|z-h0|；
wherein z represents the z-axis coordinate of the center of the missed spray region, h0Representing the vertical height of the camera pan-tilt;
3) calculating the horizontal angle theta of the industrial camera lens:
θ＝arcsin(h/D)；
the front-back distance between the industrial camera and the center of the handicraft article is as follows: d × cos θ.
The control terminal outputs the vertical distance, the front-back distance and the horizontal angle of the camera lens between the camera and the center of the handicraft, and controls the camera holder to automatically adjust the pose of the industrial camera.
In this embodiment, step S23 specifically includes: after preprocessing operations such as image filtering, image sharpening and image enhancement are carried out on the acquired image in sequence, the contours in the acquired image are extracted by adopting a K-Means clustering segmentation algorithm, and size information of each contour is obtained through morphological processing.
Step S3: automatically adjusting the control parameters of the spraying equipment according to the spraying simulation result and the real-time detection result of the spraying of the artware, replanning the spraying process of the artware and optimizing the spraying process of the artware; finally, according to the spraying simulation result and the real-time detection result of the spraying of the artware, determining the optimal parameters of the spraying equipment and transmitting the parameter results to the control terminal, and the method specifically comprises the following steps:
step S31: determining the optimal parameters of the spraying equipment according to the spraying simulation result and the real-time detection result of the spraying of the artware and transmitting the parameter results to the control terminal;
step S32: the control terminal automatically adjusts relevant parameters of the spraying equipment, and the parameters comprise: paint spraying flow, vertical running speed of a spray head, rotating speed of a rotary table of the spray head and electrostatic voltage.
In this embodiment, in step S31, the determining the optimal parameters of the spraying device specifically includes:
1) optimizing the paint spraying flow V: knowing that the average number of missed spray on the surface of a certain batch of artware is N, the spray paint flow V of the spray equipment is optimized in a grading way according to the defect information, and the expression is shown as follows. Wherein omega is the flow of spraying paint and increases progressively the parameter, and average number of leaking spouting increases 3 every time promptly, then increases spraying paint flow V of spraying equipment in grades:
V＝V'+[N/3]ω；
in the formula, V' is the initial paint spraying flow, N is the average leaked paint spraying number of the surface of the handicraft, and omega is a paint spraying flow increasing parameter;
2) optimizing the vertical running speed v of the spray head passing through a leakage spray area: the vertical speed of the spray head directly influences the paint adhesion rate of the surface unit area of the handicraft, and the area of a certain spray leakage area is S and the central vertical height is h0Then, the control terminal will regulate and control the vertical operating speed ν of the spray head according to the area size of the spraying defect in a grading manner, namely, the vertical speed of the spray head passing through the missing spraying area is reduced so as to improve the paint adhesion rate of the unit area of the area, and the formula is as follows:
ν＝ν'-10(S/S0)；
wherein v' is the initial vertical running speed, S0The surface area of the handicraft is shown, and S is the area of a leakage spraying area;
3) optimizing the rotating speed n of the nozzle rotating disc: the rotating speed of the rotary table is the factor which has the greatest influence on the atomized particle size of the coating, and if the blow-out rate of the surface of a certain batch of processes is known to be gamma, the control terminal properly increases the rotating speed n of the rotary table according to the average blow-out rate of the product to reduce the average blow-out rate of the product, and the expression is as follows:
n＝n'+1000(1+9.2γ)；
in the formula, n' is the initial rotating speed, and gamma is the blow-by rate of the surface of the handicraft;
4) optimizing the electrostatic voltage U: the electrostatic voltage is an important factor influencing the atomization effect of the coating, and the electrostatic voltage of the spraying equipment is generally controlled to be about 80kV so as to ensure that the coating is atomized fully. When the control terminal detects that the artware has defects such as missing spraying, the electrostatic voltage U of the spraying equipment is adjusted in a grading manner according to the average missing spraying rate of the product so as to improve the paint adhesion rate of the surface unit area of the artware, and the expression is as follows:
Figure BDA0002574215030000091
in the formula, U' is an initial electrostatic voltage.
And the control terminal automatically adjusts the relevant parameters of the spraying equipment according to the optimal parameter result.
Step S4: and storing the spraying simulation result of the step S1, the real-time detection result of the spraying of the artware of the step S2 and the control parameters of the spraying equipment of the step S3 into an artware surface spraying database.
The foregoing is directed to preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. However, any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention are within the protection scope of the technical solution of the present invention.

Claims (3)

1. A control method based on spraying simulation of a handicraft surface is characterized by comprising the following steps:
step S1: simulating to obtain a simulation result of spraying the surface of the handicraft;
step S2: determining the position of the missed spraying on the surface of the handicraft according to the spraying simulation result, and further carrying out image acquisition on the position of the missed spraying to obtain a real-time detection result of the spraying of the handicraft;
step S3: automatically adjusting the control parameters of the spraying equipment according to the spraying simulation result and the real-time detection result of the spraying of the artware, replanning the spraying process of the artware and optimizing the spraying process of the artware;
step S3 specifically includes the following steps:
step S31: determining the optimal parameters of the spraying equipment according to the spraying simulation result and the real-time detection result of the spraying of the artware and transmitting the parameter results to the control terminal;
step S32: the control terminal automatically adjusts relevant parameters of the spraying equipment, and the parameters comprise: spray paint flow, vertical running speed of a spray head, rotating speed of a rotary table of the spray head and electrostatic voltage;
in step S31, the determining of the optimal parameters of the spraying device specifically includes:
1) optimizing the paint spraying flow V:
V＝V'+[N/3]ω；
in the formula, V' is the initial paint spraying flow, N is the average leaked paint spraying number of the surface of the handicraft, and omega is a paint spraying flow increasing parameter;
2) optimizing the vertical running speed v of the spray head passing through a leakage spray area:
ν＝ν'-10(S/S0)；
wherein v' is the initial vertical running speed, S0The surface area of the handicraft is shown, and S is the area of a leakage spraying area;
3) optimizing the rotating speed n of the nozzle rotating disc:
n＝n'+1000(1+9.2γ)；
in the formula, n' is the initial rotating speed, and gamma is the blow-by rate of the surface of the handicraft;
4) optimizing the electrostatic voltage U:
Figure FDA0003159487230000021
in the formula, U' is initial electrostatic voltage;
step S4: and storing the spraying simulation result of the step S1, the real-time detection result of the spraying of the artware of the step S2 and the control parameters of the spraying equipment of the step S3 into an artware surface spraying database.
2. The control method based on the handicraft surface spraying simulation of claim 1, wherein the step S2 specifically comprises the following steps:
step S21: adjusting the pose of the industrial camera according to the position information of the missed spray, wherein the pose comprises the vertical distance between the camera and the handicraft, the front-back distance and the horizontal angle of a camera lens;
step S21 specifically includes: calculating the following parameters according to the central coordinates of each missing spraying area, the size of the handicraft, the focal length of the industrial camera lens and the size of the photosensitive sensor:
1) calculating the working distance D of the industrial camera:
Figure FDA0003159487230000031
in the formula, FL is the focal length of a lens of the industrial camera, FOV represents the view field of the industrial camera, and SH represents the size of the photosensitive sensor;
2) calculating the vertical distance h between the industrial camera and the center of the handicraft according to the center coordinates of the spray leakage area and the vertical height of the camera holder:
h＝|z-h0|；
wherein z represents the z-axis coordinate of the center of the missed spray region, h0Representing the vertical height of the camera pan-tilt;
3) calculating the horizontal angle theta of the industrial camera lens:
θ＝arcsin(h/D)；
the front-back distance between the industrial camera and the center of the handicraft article is as follows: d × cos θ;
step S22: adjusting the pose of the industrial camera according to the parameters calculated in the step S21, and further acquiring image information of the position of the missed spray;
step S23: and (5) carrying out contour extraction on the image of the missed spray position collected in the step S22 to obtain a real-time detection result of the spraying of the artware.
3. The control method based on the handicraft surface spraying simulation as claimed in claim 1, wherein the step S23 is specifically: and extracting the contours in the acquired images by adopting a K-Means clustering segmentation algorithm, and obtaining the size information of each contour through morphological processing.
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