JP2012125699A - Coating control system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coating control system which can accurately determine a timing when a repair paint of paintwork is necessary.SOLUTION: The coating control system 1 includes: a film thickness measuring section 31 for measuring film thicknesses t of paintworks 2a-2d; a discoloration area ratio measuring section 33 and a discoloration ratio measuring section 34 for measuring a discoloration area ratio s and a discoloration ratio c of paintworks 2a-2d, respectively, by processing a captured image of a camera 32; and a determination unit 4 for determining a timing and a range in which the repair paint of paintworks 2a-2d is necessary based on the combination of the measurement results of the film thickness t, the discoloration area ratio s, and the discoloration ratio c.

Description

  The present invention relates to a coating management system that manages a time when a painted surface needs to be repaired.

Conventionally, as a paint management system that manages the time when repair coating of multiple painted surfaces on multiple equipment and structures is required, it can be applied by quantitatively evaluating the deterioration state of the paint film on the painted surface. There is known one that determines a time when surface repair coating is required (for example, see Patent Document 1).
The coating management system described in Patent Document 1 measures a rust generation area ratio, which is a ratio of a rust generation area to the entire coating surface, by performing image processing on a captured image of a painted surface captured by a digital camera. And the time when the repair coating of the painted surface is necessary is determined based on the measured rust generation area ratio.

JP 2004-279317 A

Since the conventional coating management system measures the deterioration state of the coating film only with a single parameter (rust generation area ratio), the deterioration state of the coating film cannot be grasped in detail. For this reason, there is a problem that it is not possible to accurately determine when the painted surface needs to be repaired.
The present invention has been made in view of the above problems, and an object of the present invention is to provide a coating management system that can accurately determine when repair painting of a painted surface is necessary.

  The paint management system of the present invention for achieving the above object is a paint management system for managing the time when repair painting of a painted surface is necessary, and a paint film thickness measuring unit for measuring the thickness of the paint film on the painted surface An image capturing unit that captures the painted surface, a discoloration area rate measuring unit that measures a discolored area rate of the painted surface by performing image processing on a captured image of the image capturing unit, and a captured image of the image capturing unit. A color change rate measuring unit that measures the color change rate of the painted surface by processing, and at least two measuring units of the coating film thickness measuring unit, the discolored area rate measuring unit, and the color change rate measuring unit And a display unit for displaying a determination result of the determination unit. The determination unit determines when the repair coating is necessary based on the combination of the measurement results.

  According to the coating management system of the present invention, the deterioration state of the coating film on the painted surface is a combination of the measurement results of at least two of the coating film measurement unit, the color change area rate measurement unit, and the color change rate measurement unit. Since the time when the repair coating is necessary is determined based on this, it is possible to grasp the deterioration state of the coating film in detail as compared with the case where only a conventional single parameter is measured. As a result, it is possible to accurately determine when repaired coating is required.

In addition, the determination unit may determine the time and range in which the repair coating is necessary based on a combination of measurement results of the coating thickness measurement unit, the discoloration area rate measurement unit, and the color change rate measurement unit. preferable.
In this case, the determination means can determine not only the time when the repair coating is required but also the range where the repair coating is required, so that it is possible to manage the amount of coating required for the repair coating of the painted surface.

Further, the determination means includes a first determination unit that temporarily determines when the repair coating is necessary based on the measurement result of the coating film thickness measurement unit, and the repair based on the measurement result of the discoloration area rate measurement unit. The repair coating is based on a combination of a second determination unit that temporarily determines a range that requires painting, a temporary determination result of the first determination unit and the second determination unit, and a measurement result of the color change rate measurement unit. It is preferable to have a third determination unit that finally determines the required time and range.
In this case, the timing and range where the repair coating is required are provisionally determined by the first determination unit and the second determination unit, and the third determination unit combines these temporary determination results with the measurement results of the color change rate measurement unit. Since the final determination is made based on this, it is possible to more accurately determine the timing and range of repair coating on the painted surface.

Moreover, it is preferable that the said 1st determination part tentatively determines the time when the said repair coating is required by comparing the thickness of the coating film measured by the said coating-film thickness measurement part with a predetermined threshold value.
In this case, since the first determination unit compares the thickness of the coating film measured by the coating film thickness measurement unit with a predetermined threshold value, the first determination unit quantifies the time when repair coating is necessary and makes an objective provisional determination. Can do.

Moreover, it is preferable that the said 2nd determination part compares the discoloration area rate measured by the said discoloration area rate measurement part, and a predetermined threshold value, and tentatively determines the range which needs the said repair coating.
In this case, since the second determination unit compares the discoloration area rate measured by the discoloration area rate measurement unit with a predetermined threshold value, the second determination unit can objectively determine by quantifying the range that requires repair coating. it can.

In addition, the third determination unit adds a result obtained by comparing the color change rate measured by the color change rate measurement unit and a predetermined threshold to the provisional determination results of the first determination unit and the second determination unit. Thus, it is preferable to finally determine the time and range.
In this case, the third determination unit takes into account the result of comparing the color change rate measured by the color change rate measurement unit with a predetermined threshold value in the provisional determination results of the first determination unit and the second determination unit. It is possible to objectively make a final determination objectively by quantifying the period and range in which repair painting is required.

Moreover, it is preferable that the said 3rd determination part ranks the time and the range which require the said repair coating into several ranks, and makes the final determination.
In this case, since the final determination result by the third determination unit is ranked into a plurality of ranks, it is possible to easily grasp the time and range where the repair coating is necessary.

  According to the coating management system of the present invention, the deterioration state of the coating film can be grasped in detail, so that it is possible to accurately determine the time when the painted coating needs to be repaired.

It is a block diagram which shows the coating management system which concerns on one Embodiment of this invention. (A) is a table indicating the determination criteria of the first determination unit, (b) is a table indicating the determination criteria of the second determination unit, (c) is a table indicating the determination criteria of the third determination unit, and (d) is a final table. It is a table | surface which shows the content of the judgment rank. It is a flowchart which shows the determination procedure of a determination means.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a block diagram showing a paint management system according to an embodiment of the present invention. The coating management system 1 manages, for example, the coating state of a plurality of coating surfaces 2a to 2d that are painted on a facility device 2 such as a circuit breaker installed in a substation. More specifically, by periodically measuring the deterioration state of the coating film on each of the painted surfaces 2a to 2d, it is possible to grasp the time and range where the painted surfaces 2a to 2d are required to be repaired, and to manage the time limit for repair coating. Etc.

  The coating management system 1 includes a measuring unit 3 that measures the deterioration state of the coating film on each of the painted surfaces 2a to 2d of the facility device 2 using a plurality of parameters, and a combination of measurement results of the parameters of the measuring unit 3 based on each combination. The determination means 4 for determining the time and range where the repair coating of the painted surfaces 2a to 2d is necessary, the recording unit 5 for recording the measurement result of the measurement means 3 and the determination result of the determination means 4, and the measurement of the determination means 4 And a display unit 6 for displaying the result. In the present embodiment, a part of the measuring unit 3, the determining unit 4, the recording unit 5, and the display unit 6 are built in the mobile computer 7.

  The measuring means 3 includes a coating thickness measuring unit 31 that measures the thickness (hereinafter referred to as coating thickness) t of the coating surface 2a to 2d, and a camera (imaging unit) that images each coating surface 2a to 2d. 32, a color change area ratio measuring unit 33 that measures the color change area ratio s of each of the painted surfaces 2a to 2d by image processing the captured image of the camera 32, and each painted surface 2a by image processing the captured image. And a color change rate measuring unit 34 for measuring a color change rate c of ˜2d. Thereby, the measurement means 3 measures the deterioration state of the coating film in each coating surface 2a-2d by using the coating film thickness t, the color change area rate s, and the color change rate c as parameters.

  The coating thickness measuring unit 31 is, for example, an ultrasonic film thickness meter, which radiates ultrasonic waves from the outside of the coating toward the inside thereof, and receives the ultrasonic waves reflected on the outer surface of the equipment device 2. And the coating-film thickness t is measured by carrying out the digital conversion of the received ultrasonic wave and analyzing it. The measurement of the coating film thickness measuring unit 31 is performed at a location where chalking of the coating film or peeling of the coating film is likely to occur based on past empirical rules. A label (not shown) serving as a mark is affixed to the measurement location so that the same location can be measured every time.

  The measurement data of the coating film thickness t measured in the field by the coating film thickness measuring unit 31 is recorded in the recording unit 5 in the mobile computer 7 on the spot. The mobile computer 7 is a programmable computer having a CPU and a storage unit (not shown), and a program for executing predetermined functions is stored in the storage unit. As the functional units executed by the program, the color changing area rate measuring unit 33, the color change rate measuring unit 34, the determining unit 4, and the recording unit 5 are provided.

  The discoloration area ratio measurement unit 33 binarizes the captured image captured by the camera 32 based on a threshold value for each pixel (dot), thereby classifying the discoloration area and the non-discoloration part. The threshold value is set to a value obtained by quantifying the initial coating color of each of the painted surfaces 2a to 2d at the time when the equipment 2 is installed at the substation. Then, a discoloration area is calculated from the number of pixels corresponding to the discoloration portion, and a discoloration area ratio s that is a ratio of the discoloration area to the entire area of each of the painted surfaces 2a to 2d is calculated. The discoloration area ratio measuring unit 33 outputs the discoloration area ratio s as a measurement result.

The color change rate measurement unit 34 indicates how close the discoloration portion measured by the discoloration area rate measurement unit 33 of the captured image captured by the camera 32 approaches the rust color (red brown) from the initial paint color. Is digitized. Specifically, the initial paint color is set as a reference (0%), the rust color is set to the maximum (100%), and the color change rate c, which is the ratio of the color change in the discolored portion with respect to the rust color, is calculated. The color change rate measuring unit 34 outputs the color change rate c as a measurement result.
The measurement results output by the discoloration area rate measurement unit 33 and the color change rate measurement unit 34 are recorded in the recording unit 5.

  Based on the combination of the coating film thickness t, the color change area rate s, and the color change rate c recorded in the recording unit 5, the determination unit 4 automatically determines the time and range in which each of the painted surfaces 2a to 2d needs to be repaired. Judgment is made automatically. Specifically, the determination means 4 temporarily determines the range of the repair coating based on the first determination unit 41 that temporarily determines the time when the repair coating is necessary based on the coating film thickness t and the discoloration area rate s. A second determination unit 42 and a third determination unit that finally determines the time and range in which repair coating is necessary based on the combination of the temporary determination results of the first determination unit 41 and the second determination unit 42 and the color change rate c. 43.

2A is a table showing the determination criteria of the first determination unit 41, FIG. 2B is a table showing the determination criteria of the second determination unit 42, and FIG. 2C is a table showing the determination criteria of the third determination unit 43. , (D) is a table showing the contents of the final determination rank.
As shown in FIG. 2A, the first determination unit 41 compares the coating film thickness t measured by the coating film thickness measurement unit 31 with a predetermined threshold value t1, and temporarily determines when repair coating is necessary. judge. More specifically, when the coating film thickness t is larger than the predetermined threshold value t1, it is determined that the peeling of the coating film has not progressed, and the time when repair coating is necessary is provisionally determined as “painting unnecessary”. Moreover, the 1st determination part 41 judges that the coating film peeling etc. are advancing, when the coating film thickness t is below the threshold value t1, and designates the time which needs repair coating as "within 2-4 years". Is temporarily determined. The threshold value t1 is set to a different value depending on the coating thickness t in the initial coating state of each of the coating surfaces 2a to 2d.

  As shown in FIG. 2B, the second determination unit 42 compares the discoloration area rate s measured by the discoloration area rate measurement unit 33 with a predetermined threshold value, and temporarily determines the range where repair coating is necessary. To do. In the present embodiment, the threshold value is set to 40%, and when the discoloration area ratio s is less than 40%, it is determined that the coating film has deteriorated in a narrow range, and the range of the repair coating is “ It is temporarily determined as “partial coating”. Further, when the discoloration area ratio s is 40% or more, the second determination unit 42 determines that the coating film has deteriorated over a wide range, and temporarily determines the range of the repair coating as “all coating”. Here, “partial coating” means that the discolored portions of the painted surfaces 2a to 2d are painted, and “all paint” includes the discolored portions and the non-discolored portions of the painted surfaces 2a to 2d. This means that the entire surface is painted.

  The third determination unit 43 compares the color change rate c measured by the color change rate measurement unit 34 with a plurality of predetermined threshold values as the temporary determination results of the first determination unit 41 and the second determination unit 42. By taking into account, the final determination is made by classifying a plurality of ranks and ranges when repair painting is necessary. In the present embodiment, as shown in FIG. 2C, the plurality of threshold values are set to 20%, 40%, and 80%, and the final threshold value is compared with the color change rate c. One of the determination ranks “A” to “E” is finally determined.

FIG. 3 is a flowchart showing a determination procedure by the determination unit 4. Hereinafter, the determination procedure will be described in detail with reference to FIG.
First, it is confirmed whether or not the coating film thickness t recorded in the recording unit 5 by the first determination unit 41 is larger than the threshold value t1 (step S1). When it is larger than the threshold value t1, it is confirmed by the 2nd determination part 42 whether the discoloration area rate s currently recorded on the recording part 5 is less than 40% (step S2).

  When the discoloration area rate s is less than 40%, the third determination unit 43 confirms whether or not the color change rate c recorded in the recording unit 5 is less than 20% (step S3). When it is less than 20%, the third determination unit 43 determines that the final determination rank is “A” (painting unnecessary) (step S4).

  When the color change area rate s is not less than 40% in the step S2, or when the color change rate c is not less than 20% in the step S3, the third determination unit 43 causes the color change rate c to be 20% or more and 40%. It is confirmed whether it is less than (step S5). When it is 20% or more and less than 40%, the third determination unit 43 determines that the final determination rank is “B” (partial coating within 2 to 4 years) (step S6), and is 20% or more and 40%. If not, the third determination unit 43 determines that the final determination rank is “C” (all paintings within 2 to 4 years) (step S10).

  In step S1, if the coating film thickness t is not larger than the threshold value t1, the second determination unit 42 confirms whether or not the discoloration area ratio s is 40% or more (step S7). If it is not 40% or more, the process moves to step S3. If it is 40% or more, the process moves to step S8.

  In step S8, the second determination unit 42 confirms whether the discoloration area rate s is less than 60%. If it is less than 60%, the third determination unit 43 confirms whether the color change rate c is 40% or more and less than 80% (step S9). When it is 40% or more and less than 80%, the third determination unit 43 determines that the final determination rank is “C” (all paintings within 2 to 4 years) (step S10).

  If the color change rate c is not less than 40% and less than 80% in step S9, the third determination unit 43 checks whether the color change rate c is 80% or more (step S11). If it is 80% or more, the third determination unit 43 determines that the final determination rank is “D” (partial coating within the following year) (step S12). If it is not 80% or more, the process moves to step S10. Then, the third determination unit 43 determines the final determination rank as “C”.

  If the color change area rate s is not less than 60% in step S8, the third determination unit 43 checks whether the color change rate c is 80% or more (step S13). If it is 80% or more, the third determination unit 43 determines that the final determination rank is “E” (all paintings within the following year) (step S14), and if it is not 80% or more, the process moves to step S10. Then, the third determination unit 43 determines the final determination rank as “C”.

  The final determination result determined by the third determination unit 43 by the above determination procedure is displayed on the display unit 6 of the mobile computer 7 and can be easily confirmed at the measurement site. The final determination result is recorded in the recording unit 5 as shown in FIG. When the on-site measurement operation is completed, the data of each measurement result (coating thickness t, discoloration area rate s, and color change rate c) and final determination result data recorded in the recording unit 5 are stored in the mobile computer. 7 is uploaded to the management server 8 and accumulated.

  In the management server 8, time limit management is performed for the time when repair coating of the painted surfaces 2 a to 2 d in the plurality of facility devices 2 is necessary. The management server 8 also grasps the progress of deterioration specific to each equipment device 2 based on the past accumulated measurement results and final determination results. Thereby, the threshold value used as each determination standard of the 1st determination part 41, the 2nd determination part 42, and the 3rd determination part 43 can be suitably changed into the optimal value for every equipment apparatus 2. FIG.

  According to the coating management system 1 of the present embodiment configured as described above, the coating film deterioration state on the coating surfaces 2a to 2d is determined based on the coating thickness measuring unit 31, the discoloration area rate measuring unit 33, and the color change rate measurement. Since the determination means 4 determines when the coating surfaces 2a to 2d need to be repaired based on the combination of the three measurement results (parameters) of the section 34, compared to the conventional case of measuring only a single parameter. The deterioration state of the coating film can be grasped in detail. As a result, it is possible to accurately determine when repair coating of the painted surfaces 2a to 2d is necessary.

  In addition, the determination unit 4 determines the time and range in which the repair coating is necessary based on the combination of the measurement results of the coating thickness measurement unit 31, the discoloration area rate measurement unit 33, and the color change rate measurement unit 34. Not only the time when repair coating is necessary, but also the range of repair coating can be determined. Thereby, the coating amount required at the time of the painting of the painting surfaces 2a-2d can also be managed.

  Further, the timing and range where the repair coating is necessary are provisionally determined by the first determination unit 41 and the second determination unit 42, and the temporary determination result and the measurement result of the color change rate measurement unit 34 are determined by the third determination unit 43. Since the final determination is made based on the combination of the above, it is possible to more accurately determine the time and range in which the painted surfaces 2a to 2d need to be repaired.

Moreover, since the 1st determination part 41 is comparing the coating film thickness t measured by the coating film thickness measurement part 31 with the predetermined threshold value t1, it quantifies the time when repair coating is required, and objectively determines temporarily. can do.
In addition, since the second determination unit 42 compares the discoloration area rate s measured by the discoloration area rate measurement unit 33 with a predetermined threshold value, the range that requires repair coating is quantified and objectively determined. be able to.

In addition, the third determination unit 43 takes into account the result of comparing the color change rate c measured by the color change rate measurement unit 34 with a predetermined threshold to the provisional determination results of the first determination unit 41 and the second determination unit 42. Therefore, it is possible to objectively make a final determination objectively by quantifying the time and range in which repair painting is necessary.
Moreover, since the final determination result by the 3rd determination part 43 is classified into several ranks, the time and range which need repair coating can be grasped | ascertained easily.

The present invention is not limited to the above embodiment. For example, in the above embodiment, the deterioration state of the coating film is measured by three measurement parts (coating film thickness measurement part, discoloration area rate measurement part and color change rate measurement part), but at least two measurement parts It only has to be measured. In this case, for example, it is necessary to make a repair coating by temporarily determining when repair coating is necessary based on the measurement result of one measurement unit, and adding the measurement result of the other measurement unit to this temporary determination result. What is necessary is just to make a final decision at the right time.
In addition, although an ultrasonic film thickness meter is used as the coating thickness measuring unit, a vortex or magnetic film thickness meter may be used.

Furthermore, although the determination means performs the final determination by the third determination unit after performing the temporary determination by the first and second determination units, only the final determination may be performed by a single determination unit.
Moreover, although the coating management system of the said embodiment illustrated about the case where the coating state of the equipment of a substation is managed, it is applied also when managing the coating state of other equipment, such as a plant, or a structure. Can do.

DESCRIPTION OF SYMBOLS 1 Coating management system 2a-2d Painted surface 4 Judging means 31 Coating-film thickness measurement part 32 Camera (imaging part)
33 Color change area rate measurement unit 34 Color change rate measurement unit 41 First determination unit 42 Second determination unit 43 Third determination unit c Color change rate s Color change area rate t Coating film thickness

Claims (7)

A paint management system that manages the time when a painted surface needs to be repaired.
A coating thickness measuring unit for measuring the thickness of the coating on the coated surface;
An imaging unit for imaging the painted surface;
A color change area rate measuring unit that measures a color change area rate of the painted surface by performing image processing on a captured image of the image pickup unit;
A color change rate measuring unit that measures a color change rate of the painted surface by performing image processing on a captured image of the imaging unit;
Determination means for determining when the repair coating is necessary based on a combination of measurement results of at least two of the coating thickness measurement unit, the discoloration area rate measurement unit, and the color change rate measurement unit ,
And a display unit for displaying a determination result of the determination means.   The said determination means determines the time and range which require the said repair coating based on the combination of the measurement result of the said coating-film thickness measurement part, the said discoloration area rate measurement part, and the said color change rate measurement part. The paint management system described. The determination means includes a first determination unit that temporarily determines when the repair coating is necessary based on a measurement result of the coating film thickness measurement unit;
A second determination unit that tentatively determines a range that requires the repair coating based on the measurement result of the discoloration area rate measurement unit;
A third determination unit that finally determines the time and range in which the repair coating is required based on a combination of the temporary determination results of the first determination unit and the second determination unit and the measurement results of the color change rate measurement unit; The coating management system according to claim 2.   The coating management according to claim 3, wherein the first determination unit tentatively determines when the repair coating is necessary by comparing the thickness of the coating film measured by the coating film thickness measurement unit with a predetermined threshold value. system.   5. The coating according to claim 3, wherein the second determination unit compares the discoloration area rate measured by the discoloration area rate measurement unit with a predetermined threshold value, and tentatively determines a range where the repair coating is necessary. Management system.   The third determination unit adds a result of comparing the color change rate measured by the color change rate measurement unit and a predetermined threshold to the provisional determination results of the first determination unit and the second determination unit. The coating management system according to any one of claims 3 to 5, wherein the timing and the range are finally determined.   The said 3rd determination part is a coating management system as described in any one of Claims 3-6 which ranks the time and range which require the said repair coating into several ranks, and makes a final determination.

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