JP3827438B2 - Control method of coating film thickness in painting robot - Google Patents
Control method of coating film thickness in painting robot Download PDFInfo
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- JP3827438B2 JP3827438B2 JP08524598A JP8524598A JP3827438B2 JP 3827438 B2 JP3827438 B2 JP 3827438B2 JP 08524598 A JP08524598 A JP 08524598A JP 8524598 A JP8524598 A JP 8524598A JP 3827438 B2 JP3827438 B2 JP 3827438B2
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- coating
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Description
【０００１】
【発明の属する技術分野】
本発明は、塗装ロボットにおける塗装膜厚の制御方法に関する。
【０００２】
【従来の技術】
近年、各種の量産品の製造工程においてロボットが広く実用化されているが、船舶、橋梁などの大型構造物においても、ロボットの実用化が図られている。
【０００３】
例えば、溶接作業の多くは、溶接ロボットにより行われているが、溶接に比べて、経済効果が充分に発揮されない塗装作業においても、熟練を要する作業者の確保等の問題から、やはりロボット化が望まれている。
【０００４】
通常、塗装ロボットにより広い面積を塗装する場合、所定の塗装パスが平行にずらされ、所定の幅だけ重なるように塗装が行われるとともに、この重なり部分の幅については、従来、噴霧ノズルに基づく塗装パターン幅、すなわち塗装幅の１／３〜１／４程度に設定されていた。
【０００５】
【発明が解決しようとする課題】
上述したように、塗装の重なり部分は、塗装幅の１／３〜１／４程度にされているが、必ずしも、最適な塗装品質が得られるものではなかった。
【０００６】
そこで、本発明は、塗装ロボットによる塗装において、塗装の重なり部分での膜厚を最適なものにし得る塗装膜厚の制御方法を提供することを目的とする。
【０００７】
【課題を解決するための手段】
上記課題を解決するため、本発明の塗装ロボットにおける塗装膜厚の制御方法は、塗装ロボットのアームを所定方向に移動させながらアーム先端に設けられた噴霧ノズルから塗料を、二次関数Ｕ（ｘ）［Ｕ（ｘ）＝Ｂ−Ａｘ ２ （但し、Ａ，Ｂは係数）］にて表わされる膜厚プロフィールにしたがって噴霧するとともに、塗装方向と直角方向に所定距離だけずらせて重なり塗装を行う際に、上記重なり部分における塗装膜厚を、一方の膜厚プロフィールにおける中央部での厚さＵ Ｐ 、他方の膜厚プロフィールの縁部に対応する一方の膜厚プロフィールの厚さＵ Ｑ 、および両膜厚プロフィールの交差位置における両プロフィールの合計厚さＵ Ｒ の内、下記（Ｃ）式に示すように、最大厚さから最小厚さを減算した値Ｖが、最小となるような重なり幅（Ｗ Ｓ ／ｎ：Ｗ Ｓ は塗装パターン幅）でもって塗装を行う方法である。
上記塗装膜厚の制御方法によると、塗装幅方向にずらせて塗装を行う際の重なり部分での膜厚を最適な値にすることができる。
【０００９】
【発明の実施の形態】
以下、本発明の実施の形態の塗装ロボットにおける塗装膜厚の制御方法を、図１および図２に基づき説明する。
【００１０】
本実施の形態における塗装ロボットとしては、多関節型のものが使用されるとともに、その塗装対象物（ワーク）は船殻ブロックであり、水平方向および鉛直方向の部材により組み立てられたもので、箱型形状にされている。
【００１１】
例えば、図１に示すように、この船殻ブロック（ワークともいう）１は、船体外板２の内面に補剛部材として、ビーム材３が取り付けられるとともに、船体外板２に直交するように隔壁材４などが取り付けられたものであり、この船殻ブロック１の表面を、塗装ロボット（以下、ロボットという）により、自動的に塗装する場合について説明する。
【００１２】
本発明の要旨は、ロボットのアーム先端に設けられた塗装ガンの噴霧ノズルから塗料を広い面積の塗装面に噴霧する際に、噴霧ノズルを所定方向に移動させるとともにその移動方向すなわち塗装方向と直角方向に所定距離だけずらせて重なり塗装を行う際の重なり部分の厚さを最適な値に制御することにある。
【００１３】
そして、この重なり部分の厚さを制御する際に、塗装ロボットに、予め、塗装膜厚分布すなわち膜厚プロフィールを与えておき、この膜厚プロフィールを使用して、重なり部分の厚さが制御される。
【００１４】
まず、上記膜厚プロフィールについて説明する。
すなわち、噴霧ノズル（塗装ガンにおけるノズルチップ）からの塗料噴霧と塗布面への付着現象は複雑であるが、ノズルからの噴霧粒子がパターン幅内で均等に噴霧・付着すると仮定するならば、パターン幅内の各場所での付着粒子の密度は、ノズルからの距離および飛来粒子と塗布面との角度で決まる。
【００１５】
この要件を考慮すると、下記（１）式に示すような二次関数（放物線）を膜厚プロフィール（膜厚分布式）として採用するのが最も適している。
ｕ（ｘ）＝Ｂ−Ａｘ2・・・・（１）
上記（１）式中、ｕは膜厚を示し、ｘは塗装面における塗装パターン幅の中央からの距離を示し、またＡおよびＢは係数である。
【００１６】
次に、上記求められた膜厚プロフィールに基づき、重なり部分の最適な幅を求める手順について説明する。
まず、図２に示すように、隣接する塗装域Ｔ1，Ｔ2同士の重なり部分Ｔ3の幅Ｗを、塗装パターンＷSの１／ｎとして表わす。
【００１７】
次に、上記隣接する両塗装域Ｔ1，Ｔ2内の所定の３個所（Ｐ点，Ｑ点，Ｒ点）にて膜厚を求める。すなわち、重なり部分Ｔ3における塗装膜厚を、一方の膜厚プロフィールＦ1の中央であるＰ点での厚さＵP、他方の膜厚プロフィールＦ2の縁部に対応する一方の膜厚プロフィールＦ1のＱ点での厚さＵQ、および両膜厚プロフィールＦ1，Ｆ2の交差位置であるＲ点での両合計厚さＵRをそれぞれ求める。
【００１８】
そして、上記各厚さの内、最大厚さから最小厚さを減算した値（評価値ともいう）Ｖが、最小となるような重なり幅を求め、この重なり幅でもって塗装を行うものである。
【００１９】
上記各厚さを、式で表わすと、下記（２）式のようになり、また最大厚さから最小厚さを減算する式は、下記（３）式のようになる。
【００２０】
【数１】
そして、上記（３）式にて求められた評価値Ｖを最小にするｎを求め、この値に応じた重なり幅（ＷS／ｎ）でもって塗装を行なえば、両塗装域の重なり部分での膜厚を最適な厚さに、すなわちより均一な塗装膜厚にすることができる。
【００２２】
【発明の効果】
以上のように本発明の塗装膜厚の制御方法によると、塗装幅方向にずらせて塗装を行う際の重なり部分での膜厚を最適な値にすることができ、したがって塗装面積が広い場合でも、膜厚の変動が非常に少ない滑らかな塗装を行うことができる。
【図面の簡単な説明】
【図１】本発明の実施の形態における塗装対象物の要部鳥瞰図である。
【図２】同実施の形態における塗装膜厚の制御方法を説明する膜厚プロフィールの断面図である。
【符号の説明】
１ 船殻ブロック
２ 船体外板
３ ビーム材
４ 隔壁材[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for controlling a coating film thickness in a coating robot.
[0002]
[Prior art]
In recent years, robots have been widely put into practical use in the manufacturing processes of various mass-produced products. However, robots have also been put into practical use in large structures such as ships and bridges.
[0003]
For example, many welding operations are performed by welding robots. However, even in painting operations where the economic effect is not sufficiently exhibited compared to welding, robotization is still necessary due to problems such as securing skilled workers. It is desired.
[0004]
Normally, when a large area is painted by a painting robot, a predetermined coating path is shifted in parallel and the coating is performed so as to overlap by a predetermined width, and the width of this overlapping portion is conventionally applied based on a spray nozzle. The pattern width, that is, about 1/3 to 1/4 of the coating width was set.
[0005]
[Problems to be solved by the invention]
As described above, the overlapping portion of the coating is about 1/3 to 1/4 of the coating width, but the optimum coating quality is not necessarily obtained.
[0006]
Therefore, an object of the present invention is to provide a coating film thickness control method capable of optimizing the film thickness at the overlapping portion of the coating in the painting by the painting robot.
[0007]
[Means for Solving the Problems]
In order to solve the above-described problem, the coating film thickness control method for a painting robot according to the present invention is based on a quadratic function U (x ) When spraying according to the film thickness profile represented by [U (x) = B−Ax 2 (where A and B are coefficients)], and performing overlapping coating by shifting by a predetermined distance in the direction perpendicular to the coating direction In addition, the coating film thickness in the overlapping portion is set to the thickness U P at the center of one film thickness profile, the thickness U Q of one film thickness profile corresponding to the edge of the other film thickness profile, and both among the intersections of the thickness profile of the total thickness U R of both profiles, as shown in the following equation (C), such as a value V obtained by subtracting the minimum thickness from the maximum thickness, the minimum weight In this method, coating is performed with a width of the width (W S / n: W S is a coating pattern width) .
According to the method for controlling the coating film thickness, it is possible to optimize the film thickness at the overlapping portion when coating is performed while shifting in the coating width direction.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a method for controlling the coating film thickness in the coating robot according to the embodiment of the present invention will be described with reference to FIGS. 1 and 2.
[0010]
As the painting robot in the present embodiment, an articulated robot is used, and the object to be painted (work) is a hull block, which is assembled by horizontal and vertical members. It is in the shape of a mold.
[0011]
For example, as shown in FIG. 1, the hull block (also referred to as a work) 1 has a
[0012]
The gist of the present invention is to move the spray nozzle in a predetermined direction and perpendicularly to the moving direction, that is, the coating direction, when spraying the paint onto the coating surface of a large area from the spray nozzle of the paint gun provided at the tip of the robot arm. The purpose is to control the thickness of the overlapping portion to an optimum value when the overlapping coating is performed by shifting the direction by a predetermined distance.
[0013]
Then, when controlling the thickness of the overlapping portion, the coating robot is given a coating film thickness distribution, that is, a film thickness profile in advance, and the thickness of the overlapping portion is controlled using this film thickness profile. The
[0014]
First, the film thickness profile will be described.
That is, the spraying of paint from the spray nozzle (nozzle tip in the paint gun) and the adhesion phenomenon on the coating surface are complicated, but if it is assumed that the spray particles from the nozzle spray and adhere evenly within the pattern width, the pattern The density of the adhered particles at each location within the width is determined by the distance from the nozzle and the angle between the flying particles and the coating surface.
[0015]
Considering this requirement, it is most suitable to adopt a quadratic function (parabola) as shown in the following formula (1) as a film thickness profile (film thickness distribution formula).
u (x) = B−Ax 2 (1)
In the above formula (1), u represents the film thickness, x represents the distance from the center of the coating pattern width on the painted surface, and A and B are coefficients.
[0016]
Next, a procedure for obtaining the optimum width of the overlapping portion based on the obtained film thickness profile will be described.
First, as shown in FIG. 2, the width W of the overlapping portion T 3 between the adjacent coating areas T 1 and T 2 is expressed as 1 / n of the coating pattern W S.
[0017]
Next, the film thickness is determined at three predetermined points (P point, Q point, and R point) in the two adjacent coating areas T 1 and T 2 . That is, the coating film thickness in the overlapping portion T 3 is set to the thickness U P at the point P which is the center of one film thickness profile F 1 and one film thickness profile corresponding to the edge of the other film thickness profile F 2. obtaining thickness U Q at the point Q of F 1, and RyomakuAtsu profile F 1, both the total thickness at the point R is an intersection of the F 2 U R, respectively.
[0018]
Then, among the above thicknesses, an overlap width is obtained such that a value V (also referred to as an evaluation value) obtained by subtracting the minimum thickness from the maximum thickness is obtained, and coating is performed with this overlap width. .
[0019]
The above thicknesses are expressed by the following formula (2), and the formula for subtracting the minimum thickness from the maximum thickness is expressed by the following formula (3).
[0020]
[Expression 1]
Then, if n is obtained that minimizes the evaluation value V obtained by the above equation (3), and coating is performed with an overlapping width (W S / n) corresponding to this value, the overlapping portion of both coating areas is obtained. The film thickness can be made an optimum thickness, that is, a more uniform coating film thickness.
[0022]
【The invention's effect】
As described above, according to the coating film thickness control method of the present invention, it is possible to optimize the film thickness at the overlapping portion when coating is performed by shifting in the coating width direction, and thus even when the coating area is wide. Smooth coating with very little variation in film thickness can be performed.
[Brief description of the drawings]
FIG. 1 is a bird's-eye view of a main part of an object to be painted in an embodiment of the present invention.
FIG. 2 is a cross-sectional view of a film thickness profile for explaining a coating film thickness control method in the same embodiment.
[Explanation of symbols]
1
Claims (1)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP08524598A JP3827438B2 (en) | 1998-03-31 | 1998-03-31 | Control method of coating film thickness in painting robot |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP08524598A JP3827438B2 (en) | 1998-03-31 | 1998-03-31 | Control method of coating film thickness in painting robot |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH11276979A JPH11276979A (en) | 1999-10-12 |
| JP3827438B2 true JP3827438B2 (en) | 2006-09-27 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP08524598A Expired - Lifetime JP3827438B2 (en) | 1998-03-31 | 1998-03-31 | Control method of coating film thickness in painting robot |
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| Country | Link |
|---|---|
| JP (1) | JP3827438B2 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4480134B2 (en) * | 2004-03-15 | 2010-06-16 | 東京エレクトロン株式会社 | Coating film forming method and apparatus |
| JP2006247467A (en) * | 2005-03-08 | 2006-09-21 | Figla Co Ltd | Self-travelling working vehicle |
| KR100812725B1 (en) | 2006-10-23 | 2008-03-12 | 삼성중공업 주식회사 | Control method of position and angle for coating robot |
| CN113330276A (en) * | 2019-02-04 | 2021-08-31 | Abb瑞士股份有限公司 | Coating process and quality control of coated objects |
-
1998
- 1998-03-31 JP JP08524598A patent/JP3827438B2/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| JPH11276979A (en) | 1999-10-12 |
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