JP3003463B2 - Painting condition diagnostic device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for diagnosing a coating condition when a coating operation is performed by a coating gun.

[0002]

2. Description of the Related Art Conventionally, when a mass-produced article of an automobile body or various automobile parts is used as an object to be painted, for example, a painting gun 101 as shown in FIG. 9 is used. The coating gun 101 is configured to be supplied with a paint pressurized together with a solvent by a paint supply hose 102, and compressed air is sent from an air hose 103. Then, by pulling a lever 104 provided on the coating gun 101, the air and the paint are mixed, and the paint is discharged from the nozzle 105 by the pressure of the air. Further, the coating gun 101 is provided with a coating pattern adjusting knob 106. When the coating pattern adjusting knob 106 is turned, for example, clockwise, the range in which the atomized paint discharged from the nozzle 105 spreads has a round shape. When the adjustment knob 106 is turned to the left, a coating pattern (shaded portion indicated by reference numeral "108" in the figure) becomes a coating pattern (a hatched portion indicated by reference numeral "109" in the drawing). Further, a paint discharge amount adjustment knob 107 is provided, and
The discharge amount of the coating material from can be appropriately adjusted.

FIG. 10 shows an example of a defect such as a paint pattern. FIG. 10A shows a so-called shortness of breath in which the discharge amount of the paint is not constant or is interrupted.
Is a drawing of a crescent-shaped paint pattern, and (c) is
FIG. 4D is a diagram of a coating pattern in which the discharge amount is biased to the left or right in the discharge direction, FIG. 5D is a diagram of a paint pattern in which the discharge amount is concentrated only near the center in the discharge direction, and FIG. It is a figure of a coating pattern in the case of being small near the center of the discharge direction and increasing near the left and right ends. The painting gun 10
In the case where the object to be coated is coated using No. 1, usually, an operator actually performs the coating operation using the coating gun 101 and visually observes the change in the coating pattern and the coating quality as described above. I have to check. Then, the operator checks whether or not the change of the coating pattern, the coating quality, and the like are within a predetermined allowable range. By operating the discharge amount adjustment knob 107, the coating pattern and the discharge amount are adjusted, or various parts such as the nozzle 105 are cleaned, readjusted, or replaced to maintain and adjust the quality of the coating state. I have.

[0004]

However, such changes in the coating pattern and the checking of the coating quality in the coating operation by the conventional coating gun 101 have been performed only by visual inspection, and for many years. Because the work had to rely on the experience and know-how that had been cultivated, it largely depended on the skills of the workers who performed the checks. Therefore, the quality of the coating state varies depending on the skill level of the worker. Moreover, it is difficult for unskilled workers to judge the location of the defect based on the quality of the coating condition. As a result, there is a problem that a defective work is caused to flow out. The present invention has been made in view of the above-described problems, and an object of the present invention is to quickly and accurately diagnose a coating state and to take an appropriate countermeasure when there is a problem. It is an object of the present invention to provide a coating state diagnosis device capable of promptly informing a worker of possible information.

[0005]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a paint sprayed from a paint gun and atomized .
It is shaped into a strip-shaped slit light, and it is small
Both the laser light irradiating means for irradiating two laser beams, a plurality of laser light detecting means for detecting each of the laser beams transmitted so as to transmit the paint after being irradiated to the coating material, the laser beam Control means for comprehending a coating state in a coating operation by the coating gun based on a detection value of the detecting means and displaying the same on a display unit.

[0006]

In the case where the paint condition is checked using the paint condition diagnostic apparatus of the present invention configured as described above, a paint gun is set in the present apparatus, and data on the paint condition at the time of painting work by the paint gun. Collect. That is, when the paint is discharged from the coating gun, the laser light generated by the laser light irradiating means travels through the discharged and atomized paint and is incident on the laser light detecting means and detected. The control means collects the detected value as data. Next, with the coating gun rotated by 90 degrees, the same processing is performed again to collect data. Then, based on the data, the control means grasps a painting state in the painting operation by the painting gun and determines whether or not the painting is within an allowable range. When the control unit determines that the paint state is within the allowable range and is normal, the control unit displays on the display unit that the paint state is normal. And
During the painting work, the paint is properly discarded and sprayed, and the same processing as above is repeated to diagnose the painting state.The painting work is performed with the painting state kept within a certain allowable range. become. On the other hand, if the control unit determines that the coating state is not within the allowable range and is abnormal, the control unit displays on the display unit that the coating state is abnormal, and performs the coating operation based on preset countermeasures. Select and display the best coping method according to the status. As described above, according to the coating state diagnostic apparatus of the present invention, when a worker performs a coating operation using a coating gun, the coating state can be quickly and accurately diagnosed, and when there is a problem, , Information that can take appropriate action,
For example, the action location and action method are displayed on the display,
It is possible to inform the operator quickly.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a schematic system configuration diagram of a coating state diagnostic apparatus according to an embodiment of the present invention, FIG. 2 is a schematic block diagram of the apparatus shown in FIG. 1, and FIG. 3 is a schematic view of the beam expander shown in FIG. FIG. 4 is a distribution diagram of incident light intensity detected by the sensor shown in FIG. 2, and FIG.
FIG. 5A is an explanatory diagram of symbols used for calculating a coating state in a distribution diagram as shown in FIG. 4, and FIG. 5B is an explanatory diagram of symbols used for calculating a coating state in a sensor head shown in FIG. The same reference numerals are given to members common to the members shown in FIG. 9 and the description thereof is partially omitted.

FIG. 1 shows a coating state diagnostic apparatus 10 according to this embodiment.
As shown in (1), the sensor head unit 1, a controller 2 as a control unit, and a display unit 3,
The controller 2 calculates the painting state based on the data obtained in the sensor head unit 1 and further processes them comprehensively. For example, when there is a problem, information that can take an appropriate countermeasure in the case of a defect is provided. The information is output to the display unit 3.

As shown in FIG. 2, the sensor head section 1 includes a laser beam irradiating means 11 for irradiating a laser beam to the atomized paint discharged from the coating gun, and a laser beam irradiating the paint to irradiate the paint. Laser light detecting means 12 for detecting the laser light transmitted so as to be transmitted. The laser beam irradiating means 11 has a laser diode 13 for emitting a He-Ne laser beam La, and the laser beam La oscillated from the laser diode 13 is transmitted by a beam expander 14 disposed above the laser diode La. , Slit light Lb. As shown in FIG. 3, the beam expander 14 is configured by a group of cylindrical lenses, which are a group of several types of lenses, and is configured to shape the laser light La into strip-shaped slit light Lb. Above the beam expander 14, beam splitters 15a and 15b are provided,
Slit light L shaped by beam expander 14
b first enters the beam splitter 15a. The slit light Lb incident on the beam splitter 15a is
As shown, the light is split into a vertical slit light Lb1 and a horizontal slit light Lb2. Beam splitter 1
5b is provided at a position separated from the beam splitter 15a by a predetermined distance L to the left in the horizontal direction (FIG. 5).
(See (b)), the split slit light Lb2 is
The beam splitter 15b further splits the light into the slit light Lb3 in the vertical direction and the slit light Lb4 in the horizontal direction. The vertical slit light Lb1,
As shown in the drawing, Lb3 (corresponding to a laser beam) converts the atomized paint 16 (more precisely, a two-phase flow of paint and air) discharged from the painting gun 101 in a direction perpendicular to the slit light. Irradiate as slices. on the other hand,
The horizontal slit light Lb4 is transmitted to the beam splitter 15
The light is incident on a sensor 17 disposed adjacent to the left side in the figure b, and the output fluctuation of the laser light La oscillated from the laser diode 13 can be monitored based on the detection value of the sensor 17.

The laser beam detecting means 12 has a first sensor 18 and a second sensor 19. Painting gun 1
The slit lights Lb1 and Lb3 ejected from 01 and applied to the atomized paint 16 pass through this paint 16 and are sent vertically upward to enter the first sensor 18 and the second sensor 19, respectively. Is configured. These sensors 18 and 19 are, for example, N-channel line sensors. In this case, a distribution diagram of the incident light intensity as shown in FIG. 4 is obtained. In the distribution diagram of FIG.
The horizontal axis represents each channel, and the vertical axis represents the incident light intensity. The incident light intensity on the vertical axis indicates the intensity ratio before and after passing through the sprayed and atomized paint, and is plotted such that the origin of the coordinate axis is 100% and the upper end of the coordinate axis is 0%. . Reference numeral “20” indicates a detection value by the first sensor 18, and reference numeral “21” indicates a detection value by the second sensor 19, and generally, the detection value 20 by the first sensor 18 2 than the detection value 21 by the sensor 19
The peak of the attenuation of the incident light intensity is high, and the width of the channel exhibiting the attenuation of the incident light intensity is narrow.

The sensor head unit 1 has a holding base for a coating gun 101 (not shown), and a normal position as shown in FIG. 9 in which the air hose 103 is directed vertically downward, and a nozzle 105 of the coating gun 101. It can be accurately held at two types of positions, that is, a position rotated by 90 degrees. Further, as shown in FIG. 2, it is possible to avoid that the atomized paint discharged from the coating gun 101 scatters and adheres to the laser light irradiating means 11 and the laser light detecting means 12 and adversely affects the detection values of the respective sensors. To this end, the sensor head unit 1 is provided with a light emitting surface cleaner 22 on the side of the laser beam irradiating unit 11 and a light receiving surface cleaner 23 on the side of the laser beam detecting unit 12. These cleaners 22 and 23 are formed of a roll-up type film, and are provided with a transparent surface that is always free of stains by being wound up as appropriate, so that stable detection is ensured.

The controller 2 includes, as shown in FIG.
It is connected to the sensor head unit 1 and calculates the coating state based on the detection value obtained by the sensor head unit 1. Here, the coating state refers to the spread α, deviation δ, θ, and density I of the atomized paint discharged from the coating gun 101. The calculated paint state is not limited to these, and can be set and added as needed.

The calculation of the painting state in the controller 2 can be performed, for example, as follows.
The spread α of the paint is obtained by the following equation using the symbols shown in FIGS. 5 (a) and 5 (b). α = 2 × tan ⁻¹ ((H2−H1) / L) The deviation is expressed as a shift amount δ and a gradient θ in FIG.
Obtained by reading from the figure shown in FIG. The concentration I is similarly determined by the first sensor 18 and the second sensor 19.
Of the attenuation of the incident light intensity of the detection values 20 and 21 due to the peak I
1 and I2 are obtained by reading from the diagram shown in FIG. 5 (a) and 5 (b), C1: the theoretical center line of the discharge direction of the paint 16, C2: the actually measured center line of the discharge direction of the paint 16, I0: the amount of attenuation by paint or dust flying in the air , H1: the width of the channel exhibiting the attenuation of the incident light intensity of the detection value 20, H2: the width of the channel exhibiting the attenuation of the incident light intensity of the detection value 21, L: the separation distance between the slit lights Lb1 and Lb3. . In the above description, the same reference numerals are given to the same parts as those in FIG. 4 and the description thereof is partially omitted.

When the calculation of the painting state is completed in this way, the controller 2 performs a more comprehensive process,
An optimal countermeasure corresponding to the coating state is selected from among the countermeasures for the failure set in a storage unit (not shown) of the controller 2 in advance. Then, the controller 2 outputs this information to the display unit 3 connected to the controller 2 in order to transmit the information to the worker. The display unit 3 is not limited to a display unit, but may be a simple unit such as a printer or a display lamp as long as it can transmit information to an operator.

Next, the operation of this embodiment will be described based on the processing flow of FIG. Painting condition diagnostic apparatus 10 of the present embodiment
In the case of checking the coating state by using (1), first, the coating gun 101 is set on a holding unit (not shown) of the sensor head unit 1 (step S1). In step S2, at the start of the painting operation by the painting gun 101, initial data on the painting state is collected. That is, the lever 104 of the coating gun 101 is pulled and the nozzle 10
When the paint 16 is discharged from 5, as shown in FIG.
The two slit lights Lb1 and Lb3 generated by the laser light irradiating means 11 and separated by a predetermined distance L advance so as to pass through the discharged and atomized paint 16, and the first sensor 18 of the laser light detecting means 12 And the second sensor 19 detects the respective incident light somewhat attenuated by the paint 16. Next, with the coating gun 101 rotated by 90 degrees, the same processing as described above is performed again to obtain initial data. Then, based on the detection values detected by these sensors 18 and 19, the controller 2 shown in FIG.
(A) is internally processed to calculate the painting state, that is, the spread, offset, and density of the atomized paint discharged from the painting gun 101, and is not shown as an initial painting state. Save in the storage unit (Step S
3).

Next, the worker performs a painting operation on the object to be painted by the painting gun 101. The painting gun 101 is appropriately set on a holding portion (not shown) of the sensor head portion 1 to paint the object. Is blown out, and step S2 is performed.
Data on the coating state is collected in the same procedure as in (1) (step S4). Then, based on the detection values detected by the sensors 18 and 19, the controller 2 performs the coating state, that is, the coating gun 10 in the same procedure as in step S3.
The spread, offset, and density of the atomized paint discharged from 1 are calculated (step S5).

In step S6, the controller 2 determines whether or not the calculated painting state is within an allowable range (step S6). Here, controller 2
Is also compared with the initial painting state stored and stored in step S3, and it is checked whether there is any change in the painting state that affects the painting quality during the painting operation. If it is determined in step S6 that the coating state is within the allowable range and is normal, the controller 2 causes the display unit 3 to display on the screen that the coating state is normal (step S8). It returns to S4. Then, during the painting operation, the paint is properly thrown away, and the processing shown in steps S4, S5, S6, and S8 is repeated. The diagnosis of the painting state is performed in this way, and the painting operation is performed in a state where the painting state is kept within a certain allowable range.

On the other hand, if it is determined in step S6 that the coating state is not within the allowable range and is abnormal, the controller 2 displays on the display unit 3 that the coating state is abnormal, and stores the abnormality in the storage unit in advance. From among the set trouble countermeasures, an optimum countermeasure corresponding to the painting state is selected and displayed (step S7). At this time, a distribution diagram as shown in FIG. 5A may be displayed together.

As described above, the coating state diagnostic apparatus 10 according to the present embodiment provides the paint 16 sprayed from the coating gun 101 and atomized.
Laser light irradiating means 11 for irradiating the laser light Lb1 and Lb3 to the laser light, laser light detecting means 12 for detecting the laser light radiated to the paint 16 and transmitted through the paint, and The controller 2 has a controller 2 for grasping and processing the coating state in the coating operation by the coating gun 101 based on the detection value of the light detection means 12 and displaying the processing on the display unit 3. In the case of performing, the state of coating can be diagnosed quickly and accurately, and when there is a problem, information that can take an appropriate countermeasure, for example, a countermeasure point and a countermeasure are displayed on the display unit 3. And promptly inform the operator. Therefore, even if the painting state is not within the allowable range, the painting work may be continued without noticing, or even if a defect is noticed, the countermeasure may not be appropriate, and as a result, the defective work may flow out. Such a situation can be reliably avoided. Moreover, since the coating state diagnostic apparatus 10 of the present embodiment does not depend on the skill of the operator at all as in the prior art, even a beginner can quickly and effectively take a reliable and effective countermeasure.

FIG. 7 is a perspective view showing a painting robot 41 equipped with a painting state diagnostic apparatus according to another embodiment of the present invention.
FIG. 8 is a front view and a side view of the coating head 45 shown in FIG. The painting robot 41 has a support arm, that is, a robot arm 43, and a painting head 45 for painting an automobile body is rotatably attached to the tip of the support arm 43. As shown in the figure, a paint supply unit 47 is connected to the coating head 45 via a hose 48.
7, paint is supplied. The controller 49 controls the discharge pressure, the holding temperature, and the like of the paint supply unit 47, controls the position, tilt, speed, and the like of the support arm 43, and diagnoses the coating state described below.
As shown in FIG. 8, the coating head 45 integrally includes a coating gun 71, a laser beam irradiation unit 61, and a laser beam detection unit 62. In this embodiment, the slit light Lc1 and Lc2 in the vertical direction and the slit light Ld in the horizontal direction are
Thus, a total of four slit lights, i.e., 1 and Ld2, are generated.

Therefore, unlike the above-described embodiment, it is not necessary for the operator to rotate the coating gun 71 by 90 degrees to collect data, and it is possible to diagnose the coating state more accurately and instantly. Moreover, this embodiment can be applied to a system for performing painting in a painting line, and online diagnosis can be performed while performing painting work. Note that, when the painting state is out of the allowable range and is determined to be abnormal during the painting operation, the controller 49 outputs a command to stop the painting operation to each unit, and notifies the printer 46 that the painting state is abnormal, and The most suitable countermeasure according to the painting condition is selected from among the fault countermeasures set in advance in the storage unit and output. Thus, the occurrence of defective workpieces can be suppressed, and the same effects as in the above-described embodiment can be obtained.

The above is an embodiment of the present invention, and the present invention can be variously modified without departing from the gist of the claims. For example, an adjustment knob for adjusting the coating pattern, the discharge amount, and the like provided on the coating gun may be provided with an actuator and controlled by a controller. In this way, long-time unmanned operation becomes possible.

[0023]

As described above, the coating condition diagnostic apparatus of the present invention is capable of applying a band to the atomized paint discharged from the coating gun.
Shaped into slit-like slit light, and separated at least in parallel
Means for irradiating two laser lights,
A plurality of laser light detecting means for detecting each laser light transmitted so as to be transmitted through the paint after being irradiated on the paint, and a coating operation by the coating gun based on a detection value of the laser light detecting means. Control means for grasping the coating state of the coating and displaying it on the display unit, so when the worker performs the coating work using the coating gun,
The discharged spread of atomized paint, offset, and the coating state of concentration, etc. <br/>, it is possible to quickly and accurately diagnosed, when there is a bug in taking appropriate action Information that can be obtained, for example, a place to be dealt with and a way to deal with it can be displayed on the display unit to promptly notify the worker. Therefore, even if the painting state is not within the allowable range, you can continue painting without noticing,
Even if a defect is noticed, it is possible to surely avoid a situation in which a countermeasure is not appropriate, and as a result, a defective product work flows out. In addition, since the coating condition diagnostic apparatus of the present invention does not depend on the skill of the operator at all as in the prior art, even a beginner can take effective and reliable measures for failure quickly.

[Brief description of the drawings]

FIG. 1 is a schematic system configuration diagram of a coating state diagnosis apparatus according to an embodiment of the present invention.

FIG. 2 is a schematic block diagram of the device shown in FIG.

FIG. 3 is a configuration diagram illustrating a beam expander illustrated in FIG. 2;

FIG. 4 is a distribution diagram of incident light intensity detected by the laser light detection means shown in FIG. 2;

5A is an explanatory diagram of symbols used for calculating a coating state in a distribution diagram as shown in FIG. 4, and FIG. 5B is a diagram illustrating symbols used for calculating a coating state in a sensor head portion shown in FIG. FIG.

FIG. 6 is a diagram showing a processing flow of the apparatus shown in FIG. 1;

FIG. 7 is a perspective view showing a coating robot 41 equipped with a coating state diagnosis device according to another embodiment of the present invention.

8 is a front view and a side view of the coating head 45 shown in FIG.

FIG. 9 is a view showing a state where a paint is discharged by a paint gun.

FIG. 10 shows an example of a defect such as a paint pattern, and FIG. 10 (a) is a diagram showing a so-called shortness of breath;
(B) is a drawing of a painting pattern exhibiting a so-called crescent moon,
(C) is a drawing of a so-called paint pattern, (d) is a drawing of a so-called middle-high painting pattern, and (e) is a drawing of a so-called middle-necked painting pattern.

[Explanation of symbols]

2 ... controller (control means) 3 ... display unit, 1
0: coating state diagnosis device, 11: laser light irradiation means, 12: laser light detection means, 16
... paint, 101 ... paint gun, Lb1, Lb3 ... slit light (laser light).

Claims (1)

(57) [Claims] 1. A paint sprayed from a coating gun and atomized ,
It is shaped into a strip-shaped slit light, and it is small
Laser light irradiating means for irradiating the two laser lights, a plurality of laser light detecting means for detecting each laser light transmitted to the paint after being irradiated to the paint, and the laser light Control means for comprehending a coating state in a coating operation by the coating gun based on a detection value of the detecting means and displaying the same on a display unit.