JP3085941B2 - Continuous coating system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a continuous coating system for continuously coating building boards, and more particularly, to coating a building board having different patterns supplied one after another according to the individual patterns. To a continuous coating system.

[0002]

2. Description of the Related Art Conventionally, as a continuous coating method for ceramic building boards, JP-A-6-155729 (related to the equipment side of inkjet coating) and JP-A-7-62828 (a method of separately applying by an inkjet coating technique). Japanese Patent Application Laid-Open No. Hei 7-116597 (which relates to an ink jet coating technique and a blur coating method), and Japanese Patent Application Laid-Open No. 7-228036 (which relates to an ink jet coating technique and generates random numbers, There is a coating method using an ink jet type coating machine disclosed in, for example, a pattern), and is used for separately painting convex portions such as tiles and bricks, and for sputter coating.

[0003] According to such a coating method, spray pattern data is input to a computer memory in advance, an incoming building board is detected, and paint spraying is performed on a required painting location in accordance with the spray pattern data. By controlling the opening and closing of the valve of the nozzle, the target building board is painted. Further, by using a plurality of coating heads, a plurality of colors can be applied to one surface pattern (texture).

[0004] In addition, by controlling the contents of randomly changing the injection pattern by generating the above-mentioned random numbers, the exterior wall design of one house is made to look strange in a tile-like or brick-like manner by using a large number of building boards. It is possible to finish without. Specifically, by preventing the same pattern from being lined up at the joint between the plates, it is possible to avoid a sense of incongruity due to the repeated patterns. However, when trying to express natural feelings such as rock-slab tone and collapsed brick tone, it is difficult to express only with the same pattern of building boards, and it is necessary to use at least about four different patterns. Come.

However, according to the conventional Such processing forms, since the so intended to make continuous coating for the same pattern of the building board, in the same pattern at the same jetting pattern data basically building The plates are sequentially processed. On the other hand, there is a method in which the random numbers are separately applied using the above-mentioned random numbers, but this method also assumes that the same pattern is used for the pattern of the original plate (the building plate to be coated). I have. That is, even if the paints are randomly applied, if they are not the same pattern, a pattern shift will occur.

[0006] Therefore, at present, it is necessary to carry out continuous coating in different lots for different patterns, and as a result, at present, building boards of the same pattern are packed in the same package. It is supposed to be. Therefore, when trying to express the exterior wall design of a house with the above-mentioned different pattern configuration, the individual patterns are unpacked individually at the time of construction, and each is appropriately combined and fastened. I have to work. In that case, it is not realistic to make the contractor bear the work of combining the patterns.

On the other hand, as for the original sheet, at present, a green sheet is manufactured by press molding using a template in which four identical patterns are arranged integrally, and then subjected to heat treatment and the like, and then to a subsequent step. Is cut into four parts, and a real part is formed by cutting to manufacture four original plates having the same pattern. Therefore, in this original plate manufacturing process, if a press die 62 having four different patterns A, B, C, and D is used for the green sheet 61 (see FIG. 8 ), four different original patterns are manufactured with high productivity. It becomes possible. In that case, unless the resulting original plate having four different patterns is separated for each pattern, the original plates are put into the coating line sequentially or irregularly.

Therefore, it is conceivable that, for example, the order in which each original plate having four types of patterns is put into the coating line is determined in advance, and the order of each original plate input to the coating machine is determined. That is, control is performed to change the coating head and the spray pattern in accordance with the charging order (see FIG. 9 ).

[0009]

However, in such a control method, it is necessary to accurately match the order of feeding the original plates of different patterns with the order of using the coating head and the spray pattern. If an original plate lacking a real part is found, the defective plate must be removed from the line, and an original plate having the same pattern must be refilled so that the order is not changed. If the wrong painting is performed out of order, continuous processing will result in the production of defective paint plates one after another, and the number of defective plates will be enormous. .

[0010] At present, it is necessary to rely on manual labor because the replacement work of such a substitute original plate cannot be easily automated, and the danger of inputting the original plate with the wrong pattern is never avoided. Absent. The present invention has been made in view of the above problems, and provides a continuous coating system capable of performing coating that can flexibly respond to original patterns of different patterns that are continuously supplied according to the individual patterns. The purpose is to:

[0011]

According to the present invention, there is provided a continuous coating system comprising: an image pickup means for picking up an image of a surface shape of an original plate (a building board to be coated) before coating; Surface shape and some basic plates to be compared
By performing template matching with image data,
Pattern identification means for identifying the pattern of the original plate, and the pattern identification means
Of the original plate according to the pattern of the original plate identified by the step
Coating control means for controlling coating .

[0012]

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a diagram showing a system configuration according to an embodiment of the present invention .

The pattern identification section 20 includes an image composition memory 21 for storing composite image data of an original plate, a pattern counter 22 for counting the number of times of insertion of the identified pattern for each pattern, and several patterns of the same scale serving as a comparison reference. Template data storage unit 2 for storing template data as basic board image data
3, and an image processing unit 24 that performs image processing on the acquired individual image data. When the original plate is detected by a plate detection sensor 25 such as a limit switch for detecting whether the leading end of the original plate in the traveling direction has reached a fixed position, the image processing unit 24 is notified and the three digital cameras (1) 26, (2) 2
7. (3) 28 captures a still image of the original, combines the individual image data, and stores the combined image in the image combining memory 21. In addition, a display 31 as an image output device, a keyboard 32 as an input device, and an alarm buzzer 33 for abnormality notification are connected to the pattern identification unit 20.

The ink jet coating control unit 40, the injection pattern data storage unit 42 for storing the number of the injection pattern data corresponding to Te amplifier <br/> rate data, more injection the handle identification data from the image processing unit 24 A data correction processing unit 43 for correcting the pattern data, a processing data storage unit 44 for storing the corrected processing data, and a valve controller 4 for controlling a valve with the corrected processing data
5, and a header selection unit 46 for selecting a header based on the pattern identification data from the data correction processing unit 43. In the inkjet coating machine 47, the header is selected by the header selection unit 46, and the valve of the nozzle is controlled by the valve controller 45, thereby coating the original plate. In addition, a display 48 as an image output device and a keyboard 49 as an input device are connected to the inkjet coating control unit 20.

FIG. 2 is a diagram showing an example of a coating line.
First, the original plate is put in, a back sealer is applied as a back coat by a roll coater or the like, dried (1), a sealer is applied as an undercoat by a spray or the like, dried (2), and dried by a spray or the like. And apply a middle coat and dry (3) . Further , the convex portion is coated as a top coat using a roll coater or the like, and dried (4). In D2, the original plate was photographed, the colors of the convex portions were separately painted by ink-jet painting, sputter-painted by spraying if necessary, clear-painted by spraying, etc., dried (5), and released. Cool, check board,
Packed and shipped.

[0017]

[0018]

[0019]

[0020]

FIG. 3 is a diagram for explaining the imaging of the original 1 and the image data to be obtained. First, as a method of acquiring the surface shape data of each original plate 1, for example, a method disclosed in Japanese Patent Application No. 10-179875 (“Surface Shape Data Creation System and Recording Medium”) filed earlier is used. Can be. Specifically, since it is necessary to acquire image data with a certain degree of dimensional accuracy, a still image of the original 1 is analyzed instead of a moving image capturing analysis method. In this case, when imaging the original 1, the original 1 is temporarily stopped. In addition, even if it is a continuous coating line, since there are considerable portions where the original plate 1 stops when the direction of the original plate 1 is changed, the original plate 1 is used to acquire a still image.
Temporarily stopping is not particularly problematic in processing.

As a means for obtaining a still image, a digital camera (currently capable of obtaining a clear image of 1.5 million pixels is used) instead of a scanner in consideration of use on a production line. Shall be. Then, by creating unevenness data (distance image information) from the acquired still image data, a simple pattern such as a brick-like pattern composed of a flat convex portion, grooves on both slopes and a flat bottom portion, or a more complicated pattern It is also possible to apply the coating to the original plate 1 having the uneven surface shape pattern (for example, to apply the coating to a slope).

Since the original 1 to be imaged is long (for example, about 0.5 m in width, about 2.0 m in length, or about 3.0 m), it is divided into three parts for convenience, and each measurement part is divided into three parts. Is captured individually by three digital cameras (1) 26, (2) 27, and (3) 28, and individual image data obtained by each camera is combined by image processing to obtain an entire image of one original 1 It is assumed that 1 × m pixels (for example, no BMP (Microsoft) image data and handle as a gray scale image). It should be noted that the image a of the overlapped portion is １ ／ of each side by both adjacent cameras.
It shall be shared region, the background image is removed (see FIG. 3 b).

FIG. 4 is a view for explaining basic board image data and a pattern identification template. Separately, use in advance 4
Basic plate image data of the same scale as a reference for the design is acquired in the same manner as described above. Then, the data is processed to obtain pattern-based comparison reference image data in which respective features are extracted. (Specifically, the outline of the pattern part 2, the outline of the real part 3, the repetition unit selected by the window, and the like) made has a respective position data of the pixels constituting the respective basic texture a. see FIG. 4 a), forming it linked to each example four a, B, C, and pattern detection template of D ( see FIG. 4 b).

[0025] Then, processing line on imaged at (parts of D2 shown in FIG. 2) in operation, the synthesized image data of the original sheet 1 obtained (FIG. 3 b), all the pattern detection template (Fig. 4 b) and out to the scroll process, by performing the template matching is performed to identify the patterns included in each master plate 1, further abnormal shape of the real part 3 (e.g., the detection of cracks and chipping, etc.) . The detection of the surface pattern may be performed during the movement of the original plate 1 before entering the inkjet coating process. However, since the detection is performed by a digital camera, the convex portions and the concave portions are separately painted in consideration of the detection accuracy. It is desirable to be in the state (D2 shown in FIG. 2).

FIG. 5 is a flowchart for explaining the operation of the image processing section 24. First, it is determined whether or not the system power is ON (step S21). If NO, the process waits until the system power is turned ON. If YES, initial setting such as resetting of the pattern counter 22 is performed (step S22). For example, it is detected whether or not the leading end of the original plate 1 in the traveling direction A has reached a fixed position by a limit switch or the like and the original plate 1 is imaged. It is determined whether or not it is at the position (step S23), and if it is not at the imaging position at NO, the process waits.
Each digital camera (1) 26, (2) 27, (3) 28 is instructed to capture an image (step S25), and each camera (1) 26,
Instruct (2) 27 and (3) 28 to transfer the captured image data (step S26), synthesize the image data of one original plate from these (step S27), and perform pattern identification by template matching (step S27). Step S28), and
It is determined whether there is a shape abnormality of the real part or the like (step S2).
9) If YES is found, turn on the alarm buzzer 33
If the answer is NO and there is no abnormality, the pattern count data is added to the pattern identification data, or the shape abnormality notification data is transmitted to the data correction processing unit 43. Here, a system abnormality is detected, and if NO and there is no abnormality, the process returns to step S23. If there is an abnormality in the system, a corresponding process is performed (step S33), and the flow ends. If a defective plate is found, the operator is immediately notified of the defect, and passes the original plate 1 without performing painting.

FIG. 6 is a flowchart for explaining the operation of the data processing / correction unit 24. First, it is determined whether or not the system power is ON (step S41). If NO, the process waits until the system power is turned ON. If YES Initialize the data, and the like (step S42), performs the normal control of the ink jet coating (step S43), the input of the pattern identification data or abnormal shape contact data f header change instruction data is added It is determined whether or not there is (step S4
6) If NO and no input, return to step S43; if YES and input, determine whether or not it is pattern identification data (step S47); NO is not pattern identification data, ie If the input is the abnormal shape communication data, the valve controller 45 is instructed to close all valves (step S48), and the process returns to step S43, and YES
If the input is pattern identification data, the pattern count data is determined. If the pattern is to be changed and the header is subsequently changed to change the color, the header to be used is designated (step S5).
0), the process returns to step S43, if the does not change the header, it reads the appropriate injection pattern (step S51), the read injection pattern, and create and store correction processing data in accordance with amendments data step S
Return to 43. The paint head and spray pattern to be used are determined according to the pattern identified by the above method.

FIG. 7 is a diagram for explaining a coating control example of the present embodiment. Assuming that the four patterns are A, B, C, and D, the order and the number of times of insertion of the identified patterns are individually counted.
Then, for example, when the same pattern is counted a predetermined number of times, or when the same pattern is continuous, for example, the coating head in use is changed, or when the pattern knitting is possible, the spray pattern is changed. Perform control.

This prevents the same painted object from being continued. In general, the injection pattern is positional control data of the used nozzle. However, depending on the case, the injection amount may be changed (X1) or the injection time interval may be changed (X2). Variations can be added. Further, there may be a case where a variation element in the production of the original plate 1 partially appears in the surface shape of each original plate 1. For example, if there is a part with a slight inclination due to poor press (this can be determined from the change in the created distance data), black shade is supplied to the part to reduce the shading. It is also possible to exert an effect to be imparted.

The hue can be roughly adjusted by using two types of paints, a brown color and a black color, as a paint to be applied over the convex paint color. In addition,
The present invention is not limited to the above embodiment. A plurality of digital cameras may be provided, but one may be moved relative to the original plate.

[0031]

As described above, according to the present invention,

[0032] Also for different original sheet of patterns, it becomes possible to perform continuous coating according to pattern of each plate, at the time of the original sheet preparation, for example, by forming a relevant specific pattern of four plates fraction together Even if they are cut and separated later, it is possible to produce the coatings for the respective original plates in the same lot. Further, by randomly forming original plates having different paint patterns, it becomes possible to randomize the pattern of the building boards to be packed, and thus to facilitate the work after unpacking. Thereby, the workability is improved and the execution quality is improved.

[Brief description of the drawings]

FIG. 1 is a diagram showing a system configuration according to an embodiment of the present invention.

FIG. 2 is a diagram illustrating an example of a coating line.

FIG. 3 is a diagram illustrating imaging of an original plate and image data to be acquired according to the present embodiment.

FIG. 4 is a diagram illustrating basic plate image data and a pattern identification template according to the present embodiment.

FIG. 5 is a flowchart illustrating the operation of the image processing unit according to the present embodiment.

FIG. 6 is a flowchart illustrating an operation of a data processing correction unit according to the present embodiment.

FIG. 7 is a diagram illustrating a coating control example of the present embodiment.

FIG. 8 is a diagram illustrating a press die used in the production of an original plate.

FIG. 9 is a diagram illustrating an example of a conventional coating control.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Original board 2 Handle part 3 Real part 26, 27, 28 Digital camera (1), (2), (3) 61 Green sheet 62 Press type

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-9-187693 (JP, A) JP-A-60-200375 (JP, A) JP-A-10-97610 (JP, A) 8347 (JP, B2) (58) Fields investigated (Int. Cl. ⁷ , DB name) B05B 12/08 B05B 13/00 B05D 1/02 B05D 3/00

Claims (1)

(57) [Claims] 1. An imaging means for imaging a surface shape of an original plate (architecture board to be coated) before painting, and a surface shape imaged after imaging by the imaging means is completed.
And some basic board image data as comparison standards
By performing plate matching, the pattern of each original plate
According to a pattern identifying means for performing identification, and a pattern of the original plate identified by the pattern identifying means.
Coating control means for controlling the coating of the original plate .