JP2007000689A - Coating control method, and coating control system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily and automatically perform the setting of coating conditions in accordance with various factors, and to improve working efficiency as well. <P>SOLUTION: By automatic calculation by a coating condition calculation part 13a in an automatic calculation means 13, standard values to be the optimum coating condition per the object to be coated are obtained using various factors regarding the conditions of a coating finish held to a coating condition table 12, and, in co-operation with the operation control of a coating apparatus 23 (coating robot), spraying control by a coater is performed. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a painting control method and a painting control system by a painting robot that automatically performs settings related to painting finishing.

  2. Description of the Related Art Conventionally, in a painting robot, a test painting is performed as a preparation stage of the main painting by teaching a paint spray locus and subsequently setting various predicted painting conditions. Since the painting is repeatedly performed by the taught painting work, if there is any wasteful painting or inappropriate operation, this is repeated and sufficient teaching is required. For this reason, while checking the presence or absence of unpainted paint, the condition of the paint surface, and the paint film thickness, the operator can determine the paint conditions such as the paint spray trajectory, paint discharge rate, paint spray pressure, etc. Repeatedly adjust it so that it is optimal for (work).

  However, setting of the optimum coating conditions is not only skillful but also very time consuming. That is, the factors that affect the final finish of the painted surface are not limited to the above-described coating conditions, and there are many conditions, which are related to each other. Generally known coating conditions include paint conditions, spraying conditions of a coating machine, and conditions relating to the coating method, and naturally, the conditions of the object to be coated are added thereto.

  Furthermore, there are three major factors in the conditions of the coating machine: spraying pressure of the coating machine, spray amount of paint, and pattern opening. Specifically, the importance as an adjustment item of the coating machine, that is, the spray gun is recognized. . Also, the conditions of the coating method are recognized as the three major elements in the same manner as the spraying operation conditions: the spraying distance, the moving speed of the coating machine, and the spraying pattern coating interval or coating interval. These conditions, for example, will affect the pattern and coating if the paint discharge rate changes, and will change the coating film thickness. The spraying distance between the spray gun and the object to be coated and the movement of the spray gun It is also clear that the coating thickness changes in the same way if the speed changes.

  Therefore, many years of experience in painting work not only affects the finish of the painted surface, but also affects the amount of paint used and the time of painting. The difference affects productivity and profits, as well as resource saving, Since it affects the environment, there is always a demand for optimal coating. In a painting robot that is at the forefront of painting mechanization, these requirements are demanded in the same way or more.

In order to facilitate the setting of the coating conditions, Patent Document 1 discloses data on the coating conditions such as the paint discharge amount, the atomizing air pressure or the pattern air pressure according to the type of the object to be coated of the coating gun. Corresponding to the identification number indicating the type of the object to be coated is previously stored in the data storage means, and when the type of the object to be coated is changed, the condition setting means is entered by inputting the type number of the object to be painted. The paint condition data is called from the data storage means, and a control signal corresponding to the data is sent to the paint gun control device. When correction is required due to atmospheric conditions, the correction means calls the condition setting means. We have proposed a painting condition management system for automatic painting systems that corrects painting condition data.
Utility Model Registration No. 2555619

  By the way, in what is shown by patent document 1 mentioned above, since the data of a corresponding coating condition are obtained by inputting the kind number of a to-be-painted object in a condition setting means, comparatively skill is not required for the setting of a coating condition. It is considered a thing.

  However, the data stored in the data storage means is the paint discharge amount, atomizing air pressure or pattern air pressure according to the type of the object to be coated of the paint gun, and all of them are related to only the paint discharge. This is a limited range related to the adjustment of the spraying conditions of the above-described coating machine, and the elements related to the setting of the coating conditions are extremely small.

  Therefore, for example, according to various factors such as settings according to the characteristics of the paint, settings according to the shape and size of the object to be coated, settings according to the spraying operation, settings according to the coating device, settings according to the finish. If the painting conditions are not properly set, there is a problem in that it cannot be specified even if the spray paint is discharged, and the final finish cannot be obtained.

  In addition, the coating specifications often indicate conditions such as how many microns the dried coating thickness is, and how many seconds and minutes of coating work can be completed. Usually, the amount of paint discharged, spray pressure, etc. There is a problem that these spraying conditions must be set based on the above-mentioned other conditions and experiences without being indicated by the spraying conditions.

  The present invention has been made in view of such circumstances, and can be easily and automatically set painting conditions according to various elements, and can be painted by a painting robot capable of improving work efficiency. An object is to provide a control method and a paint control system.

  The painting control method of the present invention is a painting control method for automatically setting spraying conditions of a coating machine by a control device of a painting robot, wherein conditions relating to the specifications of painting are input, and the specification conditions are applied to the spraying conditions of the painting machine. The spraying condition value is output to the coating machine, and the spraying control of the coating machine is performed in cooperation with the operation control of the coating robot.

  Further, as a spraying condition value relating to the coating specification, a coating film thickness and a coating time per coating cycle are set, a paint discharge amount of the coating machine is calculated from a required paint amount of the coating time, and a paint discharge adjusting means And / or output as an electrical signal to the display means.

  In addition, the required amount of paint per coating cycle is based on at least the coating area of the object to be coated, the desired film thickness, the dry coating density, the spray area ratio in the trajectory, the coating efficiency, and the non-volatile content ratio of the paint. Shall be calculated.

  The painting control method of the present invention is a painting control method that automatically performs settings related to painting finishing, and paint conditions, paint conditions, object conditions, spraying operation conditions, painting equipment conditions, and finishing conditions are input. Then, it is calculated using a pre-programmed discharge amount automatic setting calculation formula, and the paint discharge adjusting means is controlled by an electric signal according to the calculation result to control the paint discharge amount of the coating machine. And

  In addition, the target flow rate data corresponding to the optimum coating condition for each object to be coated is held, and the paint discharge adjusting means corresponding to the difference by comparison between the target flow rate data and the flow rate detection data from the paint discharge adjusting means. A flow rate correction value for feedback control is obtained.

  The paint control system of the present invention is a paint control system that automatically performs settings related to paint finish, and is a means for inputting conditions relating to paint specifications and arithmetic processing so that the conditions become spraying condition values of the paint machine. And a means for outputting to the coating machine as spraying conditions, and an output means for performing coating control in cooperation with the operation control of the painting robot for operating the painting machine and the spraying control of the painting machine. Features.

  In addition, means for inputting paint conditions, object conditions, spraying operation conditions, coating equipment conditions, finishing conditions as paint specification conditions, and automatic discharge amount setting calculation programmed in advance using the paint specification conditions Means for calculating the discharge amount using an equation, means for outputting the calculation result as an electric signal, and detection data of a flow meter for detecting the flow rate from the paint flow control valve controlled by the electric signal from the output means And a correction means for enabling correction of the calculation result.

  According to the present invention, the conditions regarding the paint finishing required by the operator, that is, how much the coating film thickness is to be finished, or how long (cycle time) is applied to any object to be coated. By inputting the conditions such as whether or not to complete, the pre-programmed arithmetic processing means calculates the spray coating conditions of the coating device, that is, the adjustment required as a variable factor and calculates the easy paint discharge amount, and outputs this value By doing so, the painting is controlled, so that painting with the required painting quality and painting efficiency can be easily performed.

  For example, by inputting the time per coating cycle, the amount of paint required to obtain the film thickness at the finish and the amount of paint discharged per hour are calculated from that amount, and the paint conditions and coating Since the optimum paint discharge amount can be calculated from the painting efficiency based on the spraying operation conditions linked with the operation control of the robot, the appropriate painting conditions can be easily obtained regardless of skilled experience.

  Further, according to the present invention, in addition to inputting a specification value or a use condition value determined by a coating apparatus or a paint to be used, the condition value related to the paint finish to be a final target value is input, for example, a paint The paint discharge amount that is the reference value that is the optimum condition for each painting is calculated by automatic calculation using various factors related to finishing, so the painting conditions can be easily and automatically set according to various factors. Can do.

Embodiments of the present invention will be described below.
FIG. 1 is a diagram for explaining the outline of the painting control system of the present invention, FIG. 2 is a diagram for explaining the details of the painting control device of FIG. 1, and FIGS. 3 and 4 are painting controls of FIG. It is a figure for demonstrating the coating control method by a system.

  As shown in FIGS. 1 and 2, the paint control system includes a paint control device 10 that performs paint discharge control and operation control of a paint device (painting robot) 23, and a display unit 11 that shows paint conditions and paint states. It has. The display unit 11 is provided with a touch panel, and according to touch input to the screen, input of control data to be described later or input of operating conditions to a coating apparatus 23 having a spray gun as a spray means (not shown). Etc. can be performed. In the figure, reference numeral 20 denotes an electropneumatic valve, reference numeral 21 denotes a flow control valve, and reference numeral 22 denotes a flow meter. The electropneumatic valve 20, the flow control valve 21, and the flow meter 22 constitute a paint discharge adjusting means.

  The painting control apparatus 10 includes a painting condition table 12 and automatic calculation means 13. The painting condition table 12 holds various conditions relating to the painting specifications, which are various elements when painting. The conditions related to the coating specifications include setting data indicating the paint conditions according to the paint characteristics, setting data indicating the object conditions according to the shape and size of the object to be coated, and spraying conditions according to the spraying operation. These are various elements relating to painting, including setting data indicating, setting data indicating spraying conditions according to the coating machine, setting data indicating finishing conditions related to coating finishing, and the like.

  The paint conditions include the coating film dry density, the non-volatile content ratio, the paint characteristics, the paint viscosity, and the like, and the workpiece conditions include the shape and size of the workpiece. Further, spraying operation conditions include overspray and pitch / stroke of a painting machine moved by a painting robot. The conditions of the coating machine include the spray gun type, the specifications such as the coating efficiency, the discharge amount, the spraying pressure, the spraying conditions such as the pattern opening, and the like. As finishing conditions, there are a film appearance, a cycle time (painting time), an aesthetic finish state of the coated surface, and the like.

  In addition, conditions related to coating specifications are added or deleted as necessary, including detailed conditions not described, and are limited to these paint conditions, coating object conditions, spraying operation conditions, coating equipment conditions, and finishing conditions. However, it is also possible to include other conditions (elements) such as ambient temperature and humidity as environmental conditions. Moreover, the conditions regarding these coating specifications are held in the coating condition table 12 corresponding to each object to be coated.

  At that time, by assigning an identification number corresponding to the object to be painted to each coating condition table 12, automatic calculation of the optimum coating condition for each object by the automatic calculating means 13 is performed. It becomes possible to identify the coating condition table 12 corresponding to the object to be painted from the identification number. However, here, for convenience of explanation, conditions relating to the coating specifications for a certain object to be coated are exemplified.

  The automatic calculation means 13 is a reference value as a spraying condition value that becomes an optimum coating condition for each object to be coated by automatic calculation based on at least the conditions related to the coating specifications in the coating condition table 12 and the control data from the display unit 11. For example, a signal for controlling the spraying condition of the coating machine is output. The drawing shows an example of controlling the discharge amount of the paint among the spray conditions, and includes a spray condition calculation unit 13a, a paint display calculation unit 13b, a control correction calculation unit 13c, a flow rate correction calculation unit 13d for the discharge amount, and the like. is doing.

  The spraying condition calculation unit 13a obtains a reference value that is an optimum condition for each painting by automatic calculation based on the coating conditions held in the coating condition table 12, and generates a spraying condition control signal corresponding to the reference value. Output to the empty valve 20. Further, when the spray condition calculation unit 13a receives the control correction value and / or the flow rate correction value from the control correction calculation unit 13c and / or the flow rate correction calculation unit 13d, the spray condition in which the reference value is corrected based on the correction value. Output a control signal.

  The paint display calculation unit 13b outputs to the display unit 11 a paint display control signal for performing a simulation display according to the reference value obtained by the spray condition calculation unit 13a. In addition, as a simulation by the display part 11, what is necessary is just the display which can confirm a coating condition at least.

  The flow rate correction calculation unit 13d holds target flow rate data corresponding to the optimum spraying condition for an arbitrary object to be coated, and compares the flow rate detection data from the flow meter 22 that measures the actually discharged flow rate. When there is, the flow rate correction value corresponding to the difference is given to the spray condition calculation unit 13a. As a result, the reference value obtained in advance by the spraying condition calculation unit 13a is corrected based on the flow rate correction value, and the spraying condition control signal based on the corrected reference value is output to the electropneumatic valve 20. Feedback control of the empty valve 20 is performed. In addition, what is necessary is just to make it receive the target flow volume data hold | maintained at the flow volume correction calculating part 13d from the blowing condition calculating part 13a which performs an automatic calculation.

Next, the details of the automatic calculation by the spray condition calculation unit 13a of the automatic calculation means 13 will be described in the case of the paint discharge amount. The spray condition calculation unit 13a performs automatic calculation based on the following discharge amount automatic setting calculation formula stored in a memory (not shown) provided in the automatic calculation means 13.
Discharge rate per hour (Fo) = (Total spray drying equivalent weight / Non-bola (Nv)) ÷ (desired cycle time (Ct) x spray ratio in the trajectory (Sr))
= (Spray dry weight / coating efficiency (Te)) / non-bora (Nv) / (desired cycle time (Ct) × spraying ratio in the trajectory (Sr))
= (Coating area (Sa) x Desired film thickness (Ft) x Dry coating density (Dd)) / Coating efficiency (Te) / Non-bola (Nv) / (desired cycle time (Ct) x Spray rate in the trajectory (Sr))
= 60 × 10 ² (Sa × Ft × Dd) / (Ct × Sr × Nv × Te)
Here, non-bola (Nv) refers to the paint non-volatile content ratio.

Here, as an example of the automatic setting of the discharge amount shown in FIG. 3, the coating area (Sa) = 50 cm × 50 cm, the desired film thickness (Ft) = 10 μ, and the dry coating film density (Dd) = 1.1 g / When cm ³ , desired cycle time (Ct) = 30 sec, spray ratio (Sr) = 80% in trajectory, non-bola (Nv) = 25%, coating efficiency (Te) = 50%, automatic calculation means 13 By the automatic calculation, the discharge amount per hour (Fo) = 55 (g / min) is obtained. The discharge amount per time (Fo) is output to the electropneumatic valve 20 as the above-described spray condition control signal.

  The discharge amount control by the spray condition control signal is performed by the flow rate control valve 21. This flow control valve 21 controls the flow rate by adjusting the opening of the valve by the air pressure, and an electric signal that is output as the spray condition control signal is used as the air pressure required according to a preset paint. Accordingly, the opening is adjusted and the required flow rate is discharged. For these flow rate controls, those generally used as an apparatus method suitable for paint flow rate control are used.

Next, the coating control method will be described.
First, as shown in FIG. 4, an operating condition is given from the coating control apparatus 10 to the coating apparatus (painting robot) 23 (step S1). The operating conditions vary depending on the object to be coated, but at least the coating location, pattern width, gun angle, and spray distance. In the teaching of the painting robot, spraying operation conditions such as a stroke, a painting interval, and the number of paintings are input as a painting locus.

  Next, the spraying condition calculation unit 13a of the automatic calculation means 13 obtains the optimum coating condition for any object to be coated by automatic calculation based on the conditions regarding the coating specifications held in the coating condition table 12 (step S2). Of these coating conditions, the optimality can be finally maintained depending on the spraying conditions of the coating machine. In particular, the amount of paint discharged is influenced by many other coating specifications, and the optimum is controlled by the control. It is one of the elements that allows the condition to be obtained.

  Therefore, when obtaining the optimum coating conditions according to the paint discharge amount, first, the above-mentioned discharge conditions are calculated based on the conditions relating to the coating specifications held in the coating condition table 12 corresponding to an arbitrary object to be coated by the spray condition calculation unit 13a. The automatic calculation based on the automatic quantity setting formula is performed, and the discharge amount per hour (Fo), which is the reference value as the optimum coating condition, is output as the spray condition control signal to the electropneumatic valve 20 (step) S3).

  Thereby, the opening degree of the electropneumatic valve 20 is controlled based on the spraying condition control signal, and the coating conditions such as the amount of paint to be discharged are adjusted. At this time, the flow rate correction calculation unit 13d compares the target flow rate data corresponding to the optimum coating condition for an arbitrary object to be coated with the flow rate detection data from the flow meter 22 (step S4), and there is a difference (step S4). In step S5), a flow rate correction value corresponding to the difference is given to the spray condition calculation unit 13a.

  Thereby, the reference value calculated | required previously by the spray condition calculating part 13a is correct | amended based on the flow volume correction value (step S7), and the corrected spray condition control signal is output to the electropneumatic valve 20.

  If there is no difference between the target flow rate data and the flow rate detection data in (Step S5), the correction of the reference value by the blowing condition calculation unit 13a in (Step S6) and (Step S7) and the electropneumatic valve 20 are performed. The feedback control for is not performed (step S8).

  As described above, in the present embodiment, the optimum for each object to be coated using various elements related to the coating specifications held in the coating condition table 12 by the automatic calculation by the spray condition calculating unit 13a of the automatic calculating means 13. Since the reference value for the appropriate coating conditions is obtained and the coating control is performed in cooperation with the operation control of the coating device (painting robot) 23, the coating conditions can be easily and automatically set according to various factors. In addition, work efficiency was improved.

  Further, in the present embodiment, during the period until the painting is completed, the opening degree of the electropneumatic valve 20 is adjusted by feedback control based on the flow rate correction value from the flow rate correction calculation unit 13d so as to be an optimum coating condition. As a result, the paint finish can be made uniform.

  By entering the content required for painting control and equipment that satisfies all conditions related to the painting specifications by the painting robot, the painting robot control device sets the optimum painting conditions and paints even without special advanced knowledge. Therefore, it is possible to achieve a significant improvement in work efficiency, and it can be used in a wide range of places such as workshops and small and medium enterprises where there are no skilled workers.

It is a figure for demonstrating the outline | summary of the coating control system of this invention. It is a figure for demonstrating the detail of the coating control apparatus of FIG. It is a figure for demonstrating an example of the automatic setting of the discharge amount by the coating control system of FIG. It is a flowchart for demonstrating the coating control method by the coating control system of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Coating control apparatus 11 Display part 12 Coating condition table 13 Automatic calculating means 13a Spraying condition calculating part 13b Painting display calculating part 13c Control correction calculating part 13d Flow rate correction calculating part 20 Electropneumatic valve 21 Flow control valve 22 Flowmeter 23 Coating apparatus (Painting robot)

Claims (7)

A painting control method for automatically setting spraying conditions of a painting machine by a painting robot control device,
Enter the conditions for the paint specifications,
The calculation condition is processed so that it becomes the spraying condition value of the coating machine, and the spraying condition value is output to the coating machine,
A painting control method, wherein spraying control of a painting machine is performed in cooperation with the operation control of the painting robot.   As a spraying condition value relating to the coating specification, a coating film thickness and a coating time per coating cycle are set, a paint discharge amount of the coating machine is calculated from a required paint amount of the coating time, a paint discharge adjusting means and / or Alternatively, the paint control method according to claim 1, wherein the paint control method outputs the electric signal to the display means.   Calculate the required amount of paint per coating cycle based on at least the coating area of the object to be coated, the desired film thickness, the dry coating density, the spray area ratio in the trajectory, the coating efficiency and the non-volatile content ratio of the paint. The coating control method according to claim 1, wherein the paint control method is performed. A paint control method that automatically performs settings related to paint finish,
When paint conditions such as paint conditions, workpiece conditions, spraying operation conditions, coating equipment conditions, and finishing conditions are entered, they are calculated using the pre-programmed discharge rate setting formula, and the calculation results A paint control method characterized by controlling the paint discharge adjusting means with an electrical signal according to the control to control the paint discharge amount of the coating machine. The target flow rate data corresponding to the optimum coating condition for each object to be coated is held, and feedback control for the paint discharge adjusting means according to the difference between the target flow rate data and the flow rate detection data from the paint discharge adjusting means 5. The method of controlling coating according to claim 4, further comprising: obtaining a flow correction value for A paint control system that automatically performs settings related to paint finish.
Means for entering the conditions for the paint specifications;
Means for calculating the spraying condition value of the coating machine and outputting the spraying condition value to the coating machine;
A painting control system comprising: an output means for performing painting control in cooperation with operation control of a painting robot for operating the painting machine and spray control of the painting machine. As the paint specification conditions, there are means for inputting paint conditions, workpiece conditions, spraying operation conditions, coating equipment conditions, and finishing conditions, and a discharge amount automatic setting formula that has been programmed in advance using the paint specification conditions. The means for calculating the discharge amount using, the means for outputting the calculation result as an electric signal, and the detection data of the flow meter for detecting the flow rate from the paint flow control valve controlled by the electric signal from the output means are fed back. The coating control system according to claim 6, further comprising a correction unit that enables correction of the calculation result.

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