JP2023036461A - Coating work management system and coating work management method - Google Patents

Abstract

To enable the proper film thickness of a coating material to be formed on a coating object material when a worker manually performs coating.SOLUTION: A coating work management system comprises: a coating gun; a coating material supply device; a measurement device which measures the position and posture of the coating gun; and a coating work management device which calculates a film thickness formation pattern to be formed on the coating object material. The coating work management device holds information on a film thickness pattern associated with a coating condition, selects the film thickness pattern on the basis of the information on the film thickness pattern associated with the coating condition, the coating condition at a time of one coating and the coating gun position and posture at the time of the coating, calculates the movement speed of the coating gun from the positions and postures from time to time of the coating gun, integrates a film thickness value indicating the film thickness pattern for a certain period from the calculated movement speed of the coating gun and the selected film thickness pattern, and calculates the film thickness formation pattern to be formed on the coating object material and coordinate values thereof.SELECTED DRAWING: Figure 1

Description

The present invention relates to a coating work management system and a coating work management method, and in particular, a coating work management system suitable for forming an appropriate coating film thickness on an object to be coated when coating is performed by an operator. and a painting work management method.

BACKGROUND ART Many structures such as buildings are painted for the purpose of imparting design or protection. In particular, in moving bodies such as railroad cars and automobiles, it is necessary to smoothen the surface of the coating film in order to impart a beautiful appearance and reduce aerodynamic resistance.

Although the coating film may be a single layer, it is often multi-layered in order to ensure the property of smoothing the coating film surface. For example, when forming a coating film on a metal surface, apply and dry a rust-preventive primer after roughening the metal surface by blasting, apply putty, dry and polish to cover the unevenness of the metal surface and ensure smoothness. Surfacer coating, drying, and polishing to cover fine irregularities on the putty surface, intermediate coating, drying, and polishing, and top coating, drying, and polishing to impart design to the outermost surface.

Painting is generally performed manually by an operator or by using an automatic machine such as a robot. Workers use sprays, brushes, rollers, etc. to apply the coating, but it is difficult to quantitatively grasp the coating film thickness during coating in real time or immediately after coating, and it depends on the skill of the worker. The side to do is strong.

On the other hand, when a robot is used, capital investment is expensive, and when paint containing an organic solvent is used, explosion-proof specifications are required, further increasing the amount of capital investment. In addition, when the place where the robot is installed or the object to be coated is to be heated, a process of retracting the robot or a process of moving and heating the object to be coated is required.

In robot coating, there is a method of acquiring coating film thickness distribution by simulation. For example, Patent Literature 1 discloses a "paint film thickness simulation method" as a simulation technique. According to the simulation method of Patent Document 1, the film thickness distribution value at the coating gun position is obtained based on the reference pattern, and the film thickness distribution value is integrated to obtain the film thickness distribution value of the object to be coated.

JP-A-2006-122830

The method of Patent Literature 1 relates to robot painting and requires capital investment. Further, in general, the painting of complicated structures often depends on manual labor, and manual labor cannot be eliminated in the painting work.

In general, whether coating is performed manually by an operator or using a robot, it is necessary to pay attention to the thickness of the coating when coating is performed. If the thickness is less than the predetermined film thickness, problems such as a weaker protection by coating and a failure to obtain a necessary aesthetic appearance may occur. If it is thicker than the specified film thickness, the solvent will remain in the coating film and evaporate, causing problems such as so-called blisters and cracks, and using a large amount of paint may cause a cost increase. . In addition, when these occur in combination, the aesthetic appearance may be impaired due to unevenness or the like. In order to prevent these problems, it is necessary to secure an appropriate film thickness.

An object of the present invention is to provide a painting work management system and a painting work management method that make it possible to form an appropriate coating film thickness on an object to be coated when coating is performed manually by an operator. It is in.

The configuration of the painting work management system of the present invention is preferably a painting work management system for managing a painting work in which paint is applied to an object to be coated by spraying paint with a paint gun, a measuring device that measures the position and orientation of the coating gun from time to time, information about the paint from the coating supply device, and information about the coating gun from the measuring device that measures the position and attitude of the coating gun from time to time. and a coating work management device for calculating the film thickness formation pattern formed on the object to be coated, the coating work management device holding information on the film thickness pattern associated with the coating conditions. , the coating work management device selects a film thickness pattern based on information on the film thickness pattern associated with the coating conditions, the coating conditions at a certain coating time, and the position and posture of the coating gun at the coating time, Calculate the moving speed of the coating gun from the position and posture of the coating gun at different times, and from the calculated moving speed of the coating gun and the selected film thickness pattern, the film thickness value indicated by the film thickness pattern is calculated for a certain period of time. A film thickness formation pattern to be formed on the object to be coated and the coordinate values of the film thickness formation pattern are calculated.

According to the present invention, there is provided a coating work management system and a coating work management method that enable formation of an appropriate coating film thickness on an object to be coated when coating is performed manually by an operator. can be done.

1 is an overall configuration diagram of a coating work management system; FIG. 1 is a functional configuration diagram of a coating work management device; FIG. 1 is a hardware/software configuration diagram of a coating work management device; FIG. It is a figure which shows an example of a painting work information table. It is a figure which shows an example of a film-thickness pattern table. It is a figure which shows each example of a film thickness pattern (the 1). It is a figure which shows each example of a film thickness pattern (2). It is a figure which shows each example of a film thickness pattern (the 3rd). It is a figure which shows each example of a film thickness pattern (part 4). It is a figure which shows each example of a film thickness pattern (No. 5). It is a figure which shows an example of a coating condition table. It is a figure which shows an example of a coating gun movement speed table. It is a figure which shows an example of a film-thickness result table. It is a figure which shows an example of a film thickness formation pattern. 1 is a diagram showing a side surface of a railway vehicle as an example of an object to be coated; FIG. It is a figure explaining an example of a coordinate system. It is a figure explaining the relationship between a to-be-coated object and a coating gun. FIG. 2 is a diagram showing the relationship between the position of the coating gun, the attitude of the coating gun, and the film thickness formed on the surface of the object to be coated (No. 1). It is the figure which showed the position of a coating gun, the attitude|position of a coating gun, and the relationship of the film thickness formed on the surface of a to-be-coated object (part 2). FIG. 3 is a diagram showing the relationship between the position of the coating gun, the attitude of the coating gun, and the film thickness formed on the surface of the object to be coated (No. 3). It is a flowchart which shows the process of a coating work management apparatus (part 1). It is a flowchart which shows the process of a coating work management apparatus (part 2). FIG. 10 is a diagram for explaining formulas used in the process of selecting a film thickness pattern; FIG. 10 is a diagram illustrating formulas used in processing for calculating a film thickness formation pattern; FIG. 11 is a diagram for explaining a process of calculating a film thickness formation pattern (Part 1); It is a figure explaining the process which calculates a film-thickness formation pattern (2). It is a figure explaining the process which calculates a film-thickness formation pattern (the 3rd). FIG. 10 is a diagram showing an example of a display image when a worker uses the AR-HMD;

An embodiment of the present invention will be described below with reference to FIGS. 1 to 19. FIG.
First, the configuration of the coating work management system will be described with reference to FIGS. 1 to 3. FIG.

First, the overall configuration of the coating work management system will be described with reference to FIG.
The coating work management system is a system that supports the work to be coated 10 mainly when the coating work is performed manually. The operator 1 discharges and sprays the paint 4 from the coating gun 40 and at the same time moves the coating gun parallel to the coating surface of the object 10 to be coated, thereby spreading the paint 4 onto the coating surface of the object 10. Apply to In the following embodiments, an example in which the object 10 to be coated is a railroad vehicle will be described.

The painting work management system, as shown in FIG. , a coating work management device 100 and a coating material supply device 300 .

The coating gun 40 is a coating device that uses compressed air from a compressor (not shown) to spray a liquid such as the paint 4 in the form of a mist onto an object. A typical form of the paint gun 40 is shaped like a pistol, and the paint is sprayed by pulling the trigger.

The paint gun 40 is connected to a paint supply device 300 by a hose 50, and the amount of paint discharged from the paint gun 40 (paint flow rate) is recorded by the paint supply device that automatically mixes a plurality of paint components. and reported to the coating work management apparatus 100 via a wired or wireless network or connection line. Further, in this embodiment, the coating gun 40 is assumed to be an air gun, and is connected to a compressor (not shown) by an air hose. It shall be reported to the work management device 100 .

Further, the coating gun 40 of the present embodiment is equipped with a marker 41 that allows the user to grasp the position and orientation with respect to the object 10 to be coated. The marker 41 indicates the position of the gun by transmitting visible light, infrared rays, or radio waves, for example, and is equipped with a plurality of markers (for example, three locations) to indicate the orientation.

The position and orientation of the paint gun 40 are calculated from the position information received from the marker 41 of the paint gun 40 . As a receiving method, for example, a form in which radio waves transmitted from the marker 41 are captured by a sensor or a plurality of cameras 30 is conceivable.

Note that the coating gun 40 of this embodiment may be in any form such as an air gun, an airless gun, or an electrostatic gun.

The camera 30 is a device that captures the painting work of the worker 1 and transfers the image to the painting work management device 100 via a wired or wireless network. Further, as described above, the camera 30 may transmit the position, orientation, and moving speed of the coating gun 40 to the coating work management device 100 .

The AR-HMD 20 is a display that is worn on the head of the worker 1 and displays necessary information for painting work. For example, according to instructions from the coating work management device 100, the operator 1 is notified of the current film thickness of the object 10 to be coated, and the information is displayed to the worker so that the film thickness is not excessive or insufficient during the coating work. . Details of the user interface provided by the AR-HMD 20 will be described later.

The paint supply device 300 is a device that mixes the undiluted paint solution and solvent and supplies the paint to the coating gun 40 through the hose 50 . The amount of paint discharged is recorded from time to time and reported to the painting work management device 100 via a network or connection line.

The coating work management device 100 is a device that manages the overall coating work of the worker 1 and displays necessary information on the AR-HMD 20 . In particular, the coating work management device 100 measures the film thickness of the coating on the object 10 to be coated, the flow rate of paint discharged from the coating gun 40, the flow rate of air, and the position, orientation, and moving speed of the coating gun 40 relative to the object 10 to be coated. Calculated from The method of calculating the film thickness of the coating on the object 10 to be coated will be described later in detail.

Next, the functional configuration of the coating work management device will be described with reference to FIG.
As shown in FIG. 2, the coating work management apparatus 100 includes a coating information input unit 101, a coating amount/air amount IF (InterFace) unit 102, an imaging information IF unit 103, a film thickness pattern search unit 104, and a coating gun speed calculator. It has functional units of a unit 105 , a film thickness calculator 106 , an HMD data editing unit 107 , an HMD data output unit 108 and a storage unit 110 .

The painting information input unit 101 is a functional unit for inputting information about the painting work by the operator 1 of the painting work or the work manager. A coating amount/air amount IF (InterFace) unit 102 is a functional unit that receives the amount of paint discharged and the air flow rate from the paint supply device 300 . The imaging information/sensor information IF unit 103 is a functional unit that receives imaging information from the camera 30 and information from various sensors. The film thickness pattern search unit 104 is a functional unit that searches for a film thickness pattern (details will be described later) based on conditions related to coating. The coating gun speed calculation unit 105 is a functional unit that calculates the moving speed of the coating gun 40 based on information input from measuring devices such as the camera 30 and sensors. The film thickness calculation unit 106 is a functional unit that calculates the film thickness formed on the object to be coated based on the film thickness pattern and the moving speed of the coating gun 40 . The HMD data editing unit 107 is a functional unit that edits data for information displayed on the AR-HMD 20 . The HMD data output section 108 is a functional section that outputs data to the AR-HMD 20 . The storage unit 110 is a functional unit that stores data used by the coating work management device 100 .

The storage unit 110 contains tables such as a coating work information table 500, a film thickness pattern table 501, a film thickness pattern 502, a coating condition table 503, a coating gun movement speed table 504, a film thickness result table 505, and a film thickness formation pattern 506. is retained.

Details of each table will be described later.

Next, the hardware/software configuration of the coating work management apparatus 100 will be described with reference to FIG.
As for the hardware configuration of the painting work management device 100, for example, it is realized by a general information processing device such as a personal computer shown in FIG. However, as long as the functions shown in FIG. 2 can be executed, the system may be a system that executes the functions by means of a cloud system.

The painting work management device 100 has a form in which a processor 402, a main storage device 404, a network I/F (InterFace) 406, a display I/F 408, an input/output I/F 410, and an auxiliary storage I/F 412 are connected by a bus. ing.

The processor 402 controls each part of the coating work management device 100, loads necessary programs into the main storage device 404, and executes them. As an example of a processor, a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit) can be considered, but other semiconductor devices may be used as long as they are the subject that executes predetermined processing.

The main memory device 404 is normally composed of a volatile memory such as a RAM, and stores programs executed by the CPU 402 and data to be referred to.

A network I/F 406 is an interface for connecting with the network 5 .

A display I/F 408 is an interface for connecting a display device 420 such as an LCD (Liquid Crystal Display).

The input/output I/F 410 is an interface for connecting input/output devices. In the example of FIG. 3, a keyboard 430 and a mouse 432 as a pointing device are connected.

Auxiliary storage I/F 412 is an interface for connecting auxiliary storage devices such as HDD (Hard Disk Drive) 450 and SSD (Solid State Drive).

The HDD 450 has a large storage capacity and stores programs for executing this embodiment. The coating work management device 100 includes a coating information input program 461, a coating amount/air amount IF program 462, an imaging information IF program 463, a film thickness pattern search program 464, a coating gun speed calculation program 465, a film thickness calculation program 466, and an HMD. A data editing program 467 and an HMD data output program 468 are installed.

Painting information input program 461, painting amount/air amount IF program 462, imaging information IF program 463, film thickness pattern search program 464, painting gun speed calculation program 465, film thickness calculation program 466, HMD data editing program 467, HMD data output The program 468 includes a coating information input unit 101, a coating amount/air amount IF unit 102, an imaging information IF unit 103, a film thickness pattern search unit 104, a coating gun speed calculation unit 105, a film thickness calculation unit 106, and an HMD data editing unit. 107, a program that realizes the function of the HMD data output unit 108;

Each program may be provided by a storage medium such as a CD-ROM or DVD-ROM, or may be distributed by a program distribution server via the Internet or the like.

Next, the data structure used in the painting work management system will be described with reference to FIGS. 4 to 10. FIG.

The painting work information table 500 is a table holding information for managing painting work, and as shown in FIG. It has fields of painting location 500f, paint product name 500g, dilution ratio h, work start date and time 500i, work end date and time 500j, film thickness lower limit 500k, film thickness upper limit 500l, and post-work instruction 500m.

The work ID 500a stores an ID that uniquely identifies a painting work. The worker 500b stores a character string representing the worker or the worker's ID. The vehicle type to be painted 500c stores a character string representing the vehicle to be painted or the ID of the vehicle. The product name of the coating gun 40 input from the input device of the coating work management device 100 is stored in the coating gun product name 500d. In the nozzle diameter 500e, the value of the diameter of the ejection port of the coating gun 40 having the coating gun product name 500d is stored in units of mm. Information on the parts of the vehicle related to the painting work is stored in the painting part 500f. Information on the product name of the paint is stored in the paint product name 500g. The work start date and time 500i stores information on the date and time when the work was started in the format of yyyymmddhhmm. The work end date and time 500j stores the information of the work end date and time in the format of yyyymmddhhmm. The film thickness lower limit 500k stores the value of the lower limit of coating specified in the coating operation (the limit below which the film thickness must not be reduced) in units of μm. In the film thickness upper limit 500l, the value of the upper limit of coating specified in the coating operation (the limit specified that the film thickness must not be thicker than this) is stored in units of μm. The post-work instruction 500m stores a character string or an ID indicating the content of the work if necessary after the painting work.

The film thickness pattern table 501 is a table that holds correspondence between coating conditions and formed film thickness patterns, and as shown in FIG. , control air flow rate 501e, coating gun product name 501f, nozzle diameter 501g, gun distance 501h, horizontal angle 501i, vertical angle 501j, and film thickness pattern 501k.

Information on the product name of the paint is stored in the paint product name 501a. The dilution rate of the paint is stored in the dilution rate 501b. Dilution ratio is generally defined as (volume of paint stock solution + volume of diluent)/(volume of diluent). The value of the paint flow rate per unit time recorded by the paint supply device 300 is stored in the paint flow rate 501c in units of mL/s. The discharge air flow rate 501d stores the value of the air flow rate per unit time discharged from the coating gun 40 in units of mL/s. In the control air flow rate 501e, the value of the air flow rate per unit time controlled by the paint supply device 300 is stored in units of mL/s. The product name of the coating gun 40 is stored in the coating gun product name 501f. The value of the diameter of the ejection port of the coating gun 40 is stored in the nozzle diameter 501g in units of mm. The vertical distance between the coating gun 40 and the object 10 to be coated is stored in the gun distance 501h in units of m. The value of the horizontal angle of the tip of the coating gun 40 is stored in the horizontal angle 501i in units of degrees. The vertical angle 501j stores the vertical angle of the tip of the coating gun 40 in degrees. The film thickness pattern 501k stores a character string or an ID that uniquely indicates the film thickness pattern described below.

In the example of FIG. 5, paint product name 501a, dilution ratio 501b, paint flow rate 501c, discharged air flow rate 501d, control air flow rate 501e, coating gun product name 501f, nozzle diameter 501g, gun distance 501h, horizontal angle 501i, vertical angle Each value of 501j is converted into a character string, and the character string connected by "-" is used as the value of the film thickness pattern 501k.

As shown in FIGS. 6A to 6E, the film thickness pattern 502 is data showing the film thickness of the coating material formed on the surface of the object 10 to be coated per unit time in units of μm for each unit grid. Structure. In FIGS. 6A to 6E, the unit time is 1 s, and the unit lattice is a 10 mm square lattice. The center of the film thickness pattern 502 is the intersection of the extension line of the coating gun 40 in the nozzle direction and the surface of the object 10 to be coated.

Regarding the coating conditions, what kind of film thickness pattern is formed can be determined by conducting a coating experiment on the actual object to be coated under the coating conditions and measuring it with means such as a film thickness meter. , can be obtained by numerical calculation or computer simulation.

The painting condition table 503 is a table that holds the conditions in the actual painting work, and as shown in FIG. It has fields of paint flow rate 503g, discharge air flow rate 503h, control air flow rate 503i, gun position (x) 503j, gun position (y) 503k, gun distance 503g, horizontal angle 503m, and vertical angle 503i.

The work ID 503a stores an ID that uniquely identifies the painting work. The date and time 503b stores the date and time of work in the yyyymmddhhmmss format. The paint product name 503c stores the information of the paint product name input by the worker or administrator before the work. The dilution rate of the paint stored in the painting work information table 500 is stored in the dilution rate 503d. In the nozzle diameter 503e, the value of the diameter of the ejection port of the coating gun 40 stored in the coating work information table 500 is stored in units of mm. The product name of the coating gun 503g stores the product name of the coating gun 40 input by the operator or manager before the work. In the paint flow rate 503g, the value of the paint flow rate per unit time measured by the paint flow meter built in or external to the paint supply device 300 is stored in units of mL/s. In the discharged air flow rate 503h, the value of the air flow rate per unit time discharged from the coating gun 40 measured by the air flow meter is stored in units of mL/s. The control air flow rate 503i stores the value of the air flow rate per unit time supplied by the compressor (not shown) in units of mL/s. The gun position (x) 503j stores the x-coordinate position of the reference point of the coating gun 40 (for example, the tip of the nozzle of the coating gun 40) measured by the camera 30 or sensor in units of m. The gun position (y) 503k stores the position of the y-coordinate of the reference point of the coating gun 40 measured by the camera 30 or sensor in units of m. The gun distance 503g stores the position between the reference point of the coating gun 40 measured by the camera 30 or the sensor and the surface of the object to be coated (in this embodiment, it is equal to the z coordinate (details will be described later)). be done. The value of the horizontal angle of the tip of the coating gun 40 measured by the camera 30 or sensor is stored in the horizontal angle 503m in units of degrees. The vertical angle 503i stores the vertical angle of the tip of the coating gun 40 measured by the camera 30 or sensor in units of degrees.

The painting gun movement speed table 504 is a table that holds information about the movement speed of the painting gun 40 calculated from the time information and position information of the painting gun 40. As shown in FIG. It has fields of moving speed (x direction) 504c, moving speed (y direction) 504d, and moving speed (z direction) 504e.

The work ID 504a stores an ID that uniquely identifies the painting work. The date and time 504b stores the date and time when the moving speed of the coating gun 40 was calculated in the yyyymmddhhmmss format. The moving speed (x direction) 504c, the moving speed (y direction) 504d, and the moving speed (z direction) 504e are the x direction, y direction, and z direction calculated from the time information and position information of the coating gun 40, respectively. The moving speed value of the paint gun 40 is stored in m/s format.

The film thickness result table 505 is a table that holds information about the film thickness of the paint formed on the surface of the object to be coated 10 calculated from the coating conditions, the moving speed of the painting gun 40, and the film thickness pattern, and is shown in FIG. 505b, a film thickness formation pattern 505c, and pattern coordinates 505d.

The work ID 505a stores an ID that uniquely identifies the painting work. The date and time 505b stores the date and time calculated to form the film thickness shown in the film thickness formation pattern 505c in the yyyymmddhhmmss format. A character string or an ID indicating the film thickness formation pattern 505c is stored in the film thickness formation pattern 505c. In this embodiment, a character string is obtained by adding a prefix (RS) to the character string indicating the film thickness pattern used to generate the film thickness formation pattern. The pattern coordinate 505d stores, for example, the value of the x-coordinate and y-coordinate pair indicating the central portion of the film thickness formation pattern 505c.

As shown in FIG. 10, the film thickness formation pattern 506 is a data structure in which the film thickness of the paint formed on the surface of the object to be coated 10 during coating is shown in units of μm for each unit grid. Each unit lattice in FIG. 10 corresponds to the unit lattice of the film thickness patterns shown in FIGS. 6A to 6E.

Next, processing of the painting work management system will be described with reference to FIGS. 11 to 14C.

First, the structure of a railcar will be described as an example of the object to be coated with reference to FIG.
The outer wall 605 of the railcar 601 shown in FIG. 11 is formed of a side surface portion and a top surface portion, which is a ceiling, and these are formed of a processed material obtained by processing a metal plate. A door portion 603 and a window portion 604, which are opening and closing doors, are provided on the side portion of the railway vehicle. A pantograph 606 is provided on the upper surface of the railway vehicle. The railway vehicle is supported by the truck portion 602, and the railway vehicle 601 is moved by rotating the wheels 607 on the rails.

In this embodiment, a paint film is formed on the outer wall of the railcar by an operator spraying the paint with a coating gun 40 within a predetermined thickness range. By coating the surface of the metal material with the coating film of the embodiment, the surface of the metal material is physically protected, and direct contact with the surface of the metal material such as foreign matter and rainwater is prevented. Therefore, it is possible to effectively prevent the occurrence of metal corrosion on the surface of the metal material. Furthermore, designability can be imparted to the railway vehicle by using a colored topcoat.

Next, the premises for calculating the film thickness of the coating formed on the object to be coated by the coating work management device will be described with reference to FIGS. 12 to 14C.

In this embodiment, as shown in FIG. 12, as a coordinate system, the x-axis and y-axis of an orthogonal coordinate system are arranged on the surface of the object to be coated (railroad vehicle) 10, and the z-axis is arranged in the direction perpendicular to the surface. Allocate Therefore, the distance between the surface of the object 10 to be coated and the nozzle at the tip of the coating gun 40 is equal to the value of the z-axis.

Further, as shown in FIG. 13, a marker 41 is set on the coating gun 40, and the position and posture of the coating gun 40 are measured by the camera 30 or sensor at each time. Also, the paint flow rate per unit time sent to the coating gun 40 is measured by a paint flow meter, and the value of the air flow rate (discharged air flow rate) per unit time discharged from the coating gun 40 measured by the air flow meter. , the value of the air flow rate (control air flow rate) per unit time supplied by the compressor is measured.

Worker 1 sprays paint with paint gun 40 while moving paint gun 40 in the direction of the x-axis or y-axis and maintaining a certain distance from the surface of object 10 to be coated. At this time, the worker 1 can see information supporting the painting work together with the work status through the AR-HDM 20 .

The relationship between the distance between the coating gun 40 and the object 10 to be coated and the posture of the coating gun 40 is as shown in FIGS. 14A to 14C. As shown in FIG. 14A, when the distance between the coating gun 40 and the object 10 to be coated is long, the film formed on the surface of the object 10 to be coated becomes thin, and as shown in FIG. 14B, the coating gun 40 and the object to be coated 10 is far, the film thickness formed on the surface of the object to be coated 10 becomes thin. Also, as shown in FIG. 14C, when the coating gun 40 is tilted with respect to the surface of the object 10 to be coated, thin and thick portions are formed on the surface of the object 10 to be coated. The applied film thickness becomes non-uniform.

The coating work management device 100 of the present embodiment holds a film thickness pattern indicating the film thickness formed per unit time when coating is performed under the position, posture, and other coating conditions of the coating gun 40 as described above. ing.

Next, processing of the coating work management device will be described with reference to FIGS. 15A to 18C.

First, the worker 1 or the manager of the coating work inputs the vehicle type, information about the worker, and the product name of the coating gun through an input screen (not shown) or a command line output to the display device of the coating work management device 100. Input (S100).

Next, based on the input information, the painting work management device 100 refers to the painting work specification data (not shown) and the painting gun specification data (not shown) to obtain the painting information in the painting work information table 500. Then, information about the coating gun is set (S101).

When information on painting and information on painting guns cannot be obtained by referring to painting work specification data and painting gun specification data (for example, when the model name of the paint cannot be determined uniquely even if the vehicle model to be painted is known) etc.), the operator 1 or the manager of the painting work inputs such information to the painting work management device 100 .

Next, when the painting work operator 1 starts the painting work, the painting work management device 100 sets the work start date and time in the work start date and time 500i of the painting work information table 500 (S102).

The processing of the following S103, S104, S105 to S113 is parallel processing.

The coating work management device 100 reads the coordinate data and posture of the coating gun 40 from the camera 3 or sensor at a certain time (S103).

The coating work management device 100 also reads the paint flow rate from the paint meter and the air flow rate (discharge air flow rate, control air flow rate) from the air flow meter (S104).

In parallel with the processing of S103 and S104, based on the values read in S104 and S104, the clock information of the painting work management device 100, and the values set in the painting work information table 500, values are added to the painting condition table 503. Set (S105).

Next, the coating work management device 100 selects the optimum film thickness pattern from the film thickness patterns stored in the film thickness pattern table 501 based on the values set in the painting condition table 503 (S106).

The film thickness pattern is selected by, for example, selecting the film thickness pattern of the record in the film thickness pattern table that has the smallest distance from the value set in the painting work information table 500 shown in (Formula 1) in FIG. do.

Here, _ei (field value of the coating condition table) is the evaluation value of the field value of the coating condition table 503, and _ei (field value of the film thickness pattern table) is the evaluation of the field value of 501 of the film thickness pattern table. The value, k _i (0≦k _i ≦1), is the weighting factor for the evaluation.

In addition, the fields of the film thickness pattern table 501 and the fields of the coating condition table 503 in each item correspond to each other (paint product name 501a: paint product name 503c, dilution ratio 501b: dilution ratio 503d, paint flow rate 501c: paint flow rate 503g, Discharged air flow rate 501d: Discharged air flow rate 503h Control air flow rate 501e: Control air flow rate 503i Coating gun product name 501f: Coating gun product name 503e Nozzle diameter 501g: Nozzle diameter 503f Gun distance 501h: Gun distance 503l Horizontal angle 501i: horizontal angle 503m, vertical angle 501j: vertical angle 503n).

When the field value of the coating condition table 503 and the field value of the film thickness pattern table 501 are equal, the square of the summation term is 0, and the greater the difference between the values, the greater the value and the greater the distance. Therefore, the evaluation values of the paint product name (paint product name 501a: paint product name 503c) and the coating gun product name (painting gun product name 501j: coating gun product name 503f) are similar to those of paints and coating guns with similar specifications. It is desirable to give a value.

Also, the weighting factor k _i for each evaluation can be determined by a supervised machine learning technique.

Next, the coating work management device 100 calculates the position of the coating gun 40 at (x, y, z) at the time of the date and time 503b of the coating condition table 503 from the coordinate data and attitude of the coating gun 40 from the camera 3 or sensor at each time. A moving speed is calculated and a value is set in the coating gun moving speed table 504 (S107).

Next, the coating work management device 100 calculates the coordinate position where the film thickness is formed and the film thickness based on the value of the painting gun movement speed table 504 and the film thickness pattern selected in S106, and calculates the film thickness result. A film thickness formation pattern and its coordinate position are set in the table 505 (S108).

The coordinate position where the film thickness is formed is the intersection of the nozzle direction of the coating gun 40 and the surface of the object to be coated 10, and this is also the center position of the film thickness formation pattern.

The value of the film thickness formation pattern in the unit cell (i, j) of the film thickness formation pattern is calculated by (Equation 2) in FIG.
k of Σ in (Formula 2) is an integer of 1 or more that satisfies (Formula 3) in FIG. 17 .
Here, T is the time interval for calculating the film thickness formation pattern, and Δt is the incremental unit of time.
Also, (Formula 2) r _x and r _y are coating efficiency coefficients in the x and y directions, respectively, and are shown in (Formula 4) in FIG. 17 . This is equal to the time that the paint is sprayed for one unit cell within the time increment Δt.

The processing for calculating the film thickness formation pattern will be specifically described below with reference to FIGS. 18A to 18C.

In this example, only the film thickness formation pattern formed by movement in the x direction is shown. 100 [s]. When the moving speed in the x direction is 100 [mm/s] and the length of one side of the unit cell is 10 mm, r _x =10 [mm]/100 [mm/s]=1/10 [1/s] , which is the time interval at which paint is sprayed by the paint gun 40 in increments of time Δt.

Therefore, since the film thickness value formed as a result of forming the film thickness pattern per unit time under certain conditions is illustrated for each unit cell, the film thickness formation pattern is expressed by (Equation 2) in FIG. 18C. As shown, the x-direction painting efficiency factor r _x and the y-direction painting efficiency factor r _y are multiplied and summed for each corresponding unit cell. 18A to 18C, the film thickness pattern A-1.0-7.5-5-2. From 5-G1-1.3-0.2-0-0, at time: 10:10:02:00, RS-A-1.0-7.5-5-2.5-G1-1. It shows that a film thickness formation pattern of 3-0.2-0-0 is calculated.

Next, the painting work management device 100 refers to the painting work information table 500, the painting condition table 503, and the film thickness result table 505, and edits HMD data for output to the AR-HMD 20 (S109).

Next, the painting work management device 100 outputs the HMD data edited in S109 to the AR-HMD 20 (S110).

Next, the painting work management device 100 determines whether or not the painting work is finished (S111). As a criterion for determining whether the painting work is finished, the working time of the painting work may be determined in advance and compared with it. You can also enter a command.

When the painting work is not finished (S111: NO), the painting work management device 100 determines whether or not the interval T has passed since the previous process (S113), and when the interval T has passed (S113: YES), Return to S105.

When the painting work is completed (S111: YES), the painting work management device 100 sets the work end date and time in the work end date and time 500j of the painting work information table 500 (S120).

Next, the painting work management device 100 stores information about instructions after finishing the painting work in the post-work instructions 500m of the painting work information table 500, and ends the process.

For example, the following examples are conceivable.
1) In the film thickness formation pattern shown in the film thickness result table 505, when the number of unit cells whose film thickness is less than the lower limit of the film thickness regulation is greater than a predetermined threshold value, repainting of a predetermined portion is instructed.
2) In the film thickness formation pattern shown in the film thickness result table 505, if the number of unit cells whose film thickness exceeds the upper limit of the film thickness regulation is greater than a predetermined threshold value, instruct repair such as polishing after drying the paint.
3) If the reason for the end of the work is that the worker has come to rest, the time to resume the painting work is instructed.

Next, the AR-HDM display image displayed to the painting worker will be described with reference to FIG.
As the HDM display image 700 of the AR-HDM 20, a time view 710, a work information view 720, a remote view 730, an enlarged view 740, a painting condition view 750, and a STATUS view 760 are displayed as shown in FIG.

A time view 710 displays to the operator the current time and the time since the start of painting. The work information view 720 displays necessary information from the painting work information table 500 to the operator. A remote view 730 displays a display image when the object 10 to be coated is viewed. In the enlarged view 740, the film thickness formation pattern shown in the film thickness result table 505 is referenced, and the state of coating on the object 10 to be coated is enlarged and displayed. For example, as shown in FIG. 19, for each unit lattice, whether the film thickness is appropriate, exceeds the specified specification, or does not meet the specified specification is displayed in different colors. For example, a unit cell within the film thickness specification is displayed in white, a unit cell not reaching the lower film thickness limit is displayed in blue, and a unit lattice exceeding the film thickness upper limit is displayed in red. The area of the object 10 to be painted displayed in the enlarged view 740 may be the area near the area currently being painted, or the area of the object 10 to be painted that the operator wants to see may be specified.

The coating work management device 100 can instruct the coating operator 1 to repeat coating when the number of unit lattices within the film thickness specification is greater than or equal to a predetermined threshold during coating. In addition, it is possible to issue an instruction for wiping off the portion where the film thickness exceeds the upper limit during coating.

The painting condition view 750 displays necessary information from the painting condition table 503 . The STATUS view 760 displays the current status that the operator wants to know, for example, a warning display when the coating film thickness exceeds the upper limit of the specification, as shown in FIG. Alternatively, when an area where the film thickness of the coating is less than the lower limit of the specification occurs over a certain area, a warning to that effect is issued.

As the HDM display image 700 of the AR-HDM 20, only the remote view 730 may be displayed at all times, and a required view area may be displayed by the operator 1's command input.

As described above, according to the present embodiment, the coating work management device selects a film thickness pattern to be applied according to the coating work, considers the movement speed of the coating gun, and actually determines the thickness of the coating film formed on the object to be coated. A thickness formation pattern is calculated, and the information is displayed in real time on the AR-HDM of the operator.

As a result, in manual painting by workers, the coating quality is improved by making the coating film thickness uniform, and by securing the minimum value of the specified film thickness, protection and beauty are secured, and the amount of paint used is reduced. By minimizing the coating cost can be minimized.

[Creation of film thickness pattern]
First, an aluminum plate was prepared as the object 10 to be coated. Specifically, among Al—Mg—Si alloys (6000 series aluminum alloys), 6N01 alloy with a smooth surface was used. The size is 1 m long, 1.2 m wide, and 2 mm thick.

The aluminum plate of the object 10 to be coated was erected vertically, and primer coating was applied. For primer coating, an automatic mixer was used to mix Uniepoc 30 primer NC red rust coating solution (manufactured by Nippon Paint) and Uniepoch 30 primer curing agent (manufactured by Nippon Paint) at a weight ratio of 6:1. The paint flow rate was varied between 5 and 30 mL/sec corresponding to the value defined in the paint flow rate 501c of the film thickness pattern table 501 of FIG. 5 shown in the embodiment. Also, the discharged air flow rate was varied between 7.5 and 32.5 mL/sec. Further, the coating gun 40 with a nozzle diameter of 1.3 mm was changed from 0.2 to 0.5 m from the aluminum plate to be coated, with a horizontal angle of 0 to 30° and a vertical angle of 0 to 30°.

The film thickness of the coating film applied under the above conditions was measured using an eddy current film thickness meter over the entire area where the coating film exists at intervals of 10 mm vertically and horizontally with the center of the coated film as the origin.

The film thickness patterns shown in FIGS. 6A to 6E are stored in the film thickness pattern table 501 in association with the conditions.

[Coating on object to be coated]
First, a similar aluminum plate was prepared as the object 10 to be coated. The specific specifications are the same as in the case of creating a film thickness pattern, 6N01 alloy among Al-Mg-Si alloys (6000 series aluminum alloys), the size is 1 m long × 1.2 m wide, The thickness was 2 mm and the smooth surface was used.

A blasting treatment was performed to ensure adhesion between the object to be coated and the coating film. The blasting was performed by spraying crushed steel particles with a particle diameter of 0.5 mm as an abrasive onto the target aluminum plate at a projection speed of 35 m/s. After the spraying was completed, an air blow was performed, and it was visually confirmed that there was no residual abrasive.

The coating was carried out in the same manner as when the film thickness pattern was created. For primer coating, an automatic mixer was used to mix Uniepoc 30 primer NC red rust coating solution (manufactured by Nippon Paint) and Uniepoch 30 primer curing agent (manufactured by Nippon Paint) at a weight ratio of 6:1. As shown in the coating condition table 503 of FIG. 7, the paint flow rate was set to 5 mL/sec, and the discharged air flow rate was set to 7.5 mL/sec. Also, an air coating gun with a nozzle diameter of 1.3 mm was kept at a distance of 0.2 to 0.3 m from the aluminum plate to be coated, and the horizontal and vertical angles were changed between 0°±30°.

The coordinate position and orientation of the coating gun 40 were calculated from camera images of three LED light emitters attached to the coating gun 40 as markers 41 . Also, the moving speed was calculated from the time and the measured coordinate position. For the film thickness, as shown in FIGS. 18A to 18C, a film thickness pattern per unit time produced under the same conditions as the coating conditions is selected, the film thickness is reduced to 1/10, and the moving direction and moving speed are changed. The film thickness formation pattern was calculated by accumulating the coordinate positions according to .

The coating film thickness specification value was set to 40 to 50 μm. In addition, the display on the AR-HMD 20 is set to white if the film thickness is within the specification range, blue if the film thickness is less than 40 μm, and red if the film thickness is greater than 50 μm, as shown in FIG. As shown in the figure, the thickness of each unit lattice is indicated by numerical value and each color. The coating was repeated several times, and the number of film thickness patterns was added according to the number of times of coating.

The film thickness after coating was measured with an eddy current type film thickness meter. AR-HMD20 shows a film thickness of 35 to 39 μm at the location marked in blue, a thickness of 40 to 50 μm at the location displayed in white, and a thickness measurement at the location displayed in red. was confirmed to be thicker than 50 μm.

1 worker, 20 AR-HMD (Augmented Reality Head Mounted Display), 30 camera, 40 painting gun, 100 painting work management device, 300 paint supply device 101 painting information Input section 102 Coating amount/air amount IF (Interface) section 103 Imaging information IF section 104 Film thickness pattern search section 105 Coating gun speed calculation section 106 Film thickness calculation section 107 HMD data Editing unit 108 HMD data output unit 110 Storage unit 500 Painting work information table 501 Film thickness pattern table 502 Film thickness pattern 503 Painting condition table 504 Painting gun movement speed table 505 Film thickness result table, 506... Film thickness formation pattern

Claims (9)

A coating work management system for managing a coating work of coating an object to be coated by spraying paint with a coating gun,
a paint supply device that supplies paint to the paint gun;
a measuring device for measuring the position and orientation of the coating gun from time to time;
Information about paint from the paint supply device and information about the paint gun from a measuring device that measures the position and orientation of the paint gun from time to time are input, and the film thickness formation pattern formed on the object to be coated is calculated. Equipped with a painting work management device that calculates
The painting work management device includes:
Holds information on film thickness patterns associated with coating conditions,
The painting work management device includes:
selecting a film thickness pattern based on information on the film thickness pattern associated with the coating conditions, the coating conditions at a certain coating time, and the position and posture of the coating gun at the coating time;
calculating the moving speed of the coating gun from the position and posture of the coating gun at different times;
Based on the calculated moving speed of the coating gun and the selected film thickness pattern, the film thickness value indicated by the film thickness pattern is integrated for a certain period of time, and a film thickness formation pattern formed on the object to be coated is obtained. and a coating work management system, wherein coordinate values of said film thickness formation pattern are calculated. In the painting work management system according to claim 1,
A painting work management system, wherein the painting conditions include information on the paint used for painting, information on the painting gun, and air flow rate sent to the painting gun. In the painting work management system according to claim 1,
In addition, it is equipped with a head-mounted display that is worn by a painting worker and displays the object to be painted and information necessary for painting work,
The coating work management device outputs information on the film thickness indicated in the film thickness formation pattern to the head mounted display,
The coating work management system, wherein the head-mounted display displays information about the film thickness indicated in the input film thickness formation pattern. A painting work management method for a painting work management system for managing a painting work of painting an object to be painted by spraying paint with a paint gun,
Painting work management system
a paint supply device that supplies paint to the paint gun;
a measuring device for measuring the position and orientation of the coating gun from time to time;
Information about paint from the paint supply device and information about the paint gun from a measuring device that measures the position and orientation of the paint gun from time to time are input, and the film thickness formation pattern formed on the object to be coated is calculated. A painting work management device to calculate,
Equipped with a head-mounted display that is worn by a painting worker and displays the object to be painted and information necessary for the painting work,
The painting work management device includes:
a film thickness pattern table that stores information on film thickness patterns associated with coating conditions;
a coating condition table that stores the time of coating, the coating conditions at the time of coating, the position and posture of the coating gun at the time of coating, and the film thickness pattern in association with each other;
a painting gun movement speed table that stores the speed of the painting gun at a certain time;
holding a film thickness result table that stores coating times, coordinate values, and film thickness formation patterns in association with each other;
a step in which the coating work management device stores the coating conditions at the time of coating and the position and posture of the coating gun at the time of coating in the coating condition table;
The coating work management device determines a coating thickness pattern based on the coating thickness pattern table, the coating conditions at the coating time stored in the coating condition table, and the coating gun position and posture at the coating time. a step of selecting;
a step in which the coating work management device calculates the moving speed of the coating gun at the time of the coating and stores it in the coating gun moving speed table;
The coating work management device integrates, for a certain period of time, the film thickness value indicated by the selected film thickness pattern based on the speed of the coating gun at a certain time stored in the table of moving speed of the coating gun. a step of calculating a thickness formation pattern and a coordinate value of the film thickness formation pattern, and storing the coating time, the coordinate value, and the film thickness formation pattern in association with each other in the film thickness result table;
A step in which the painting work management device edits display data for the head-mounted display to be displayed on the head-mounted display including information about the film thickness value indicated by the film thickness formation pattern, and outputs the display data to the head-mounted display. A painting work management method characterized by comprising: In the painting work management method according to claim 4,
The film thickness pattern information associated with the coating conditions stored in the film thickness pattern table is obtained by performing coating experiments on the actual object to be coated under the coating conditions, or by numerical calculation or computer simulation. A coating work management method characterized by: In the painting work management method according to claim 4,
In the step of selecting the film thickness pattern,
A distance between the coating condition indicated by the film thickness pattern table and the coating condition at the time of the coating stored in the coating condition table is calculated, and the film thickness pattern of the film thickness pattern table that is close to the distance is calculated. 5. The painting work management method according to claim 4, wherein a selection is made. In the painting work management method according to claim 6,
The calculation of the distance between the coating conditions indicated by the film thickness pattern table and the coating conditions at the time of the coating stored in the coating condition table is calculated by the sum of the squares of the weighted differences for each condition. A painting work management method characterized by: In the painting work management method according to claim 7,
The painting work management method, wherein the weighting coefficient used for calculating the distance is obtained by learning supervised data. In the painting work management method according to claim 4,
The film thickness pattern is a film thickness value of the paint formed in each unit cell in unit time,
For each of the x and y directions on the surface of the object to be coated, the film thickness value indicated by each unit lattice of the film thickness pattern was obtained by dividing the size of one side of the unit lattice by the moving speed of the coating gun in the x direction. multiplied by a coefficient obtained by dividing the size of one side of the unit cell by the moving speed of the coating gun in the y direction, and the value integrated for a certain period at each increment of time is calculated as the film thickness. A coating work management method, characterized in that a film thickness value indicated by each unit cell of a formation pattern is obtained.

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