JP6147118B2 - Sealer applicator - Google Patents

Description

  The present invention relates to a sealer coating apparatus that continuously applies a sealer to a surface to be coated of a workpiece.

  2. Description of the Related Art Conventionally, an automobile body has many places where a sealer is applied in order to ensure waterproofness, and the sealer application at the places is generally performed using a sealer application apparatus.

  For example, a sealer coating apparatus disclosed in Patent Document 1 includes a coating unit that continuously applies a sealer to an application surface of a workpiece, and a laser projection that irradiates a laser slit light onto the application surface on which the sealer is applied. An optical machine, a camera that shoots an irradiation line generated by irradiation of the laser projector to the sealer applied to the surface to be coated from an angle inclined with respect to an irradiation axis of the laser projector, and the captured image And determining means for determining whether or not the calculated sealer coating width deviates from a reference value.

JP 2006-167620 A (paragraphs 0013 to 0016, FIGS. 1 and 4)

  However, in Patent Document 1, it is necessary to irradiate a laser slit light for each inspection portion of the sealer applied to the surface to be coated and photograph it with a camera, and the inspection is complicated. Moreover, in order to inspect the sealer applied to the surface to be coated, not only a camera but also a laser projector is required, so that the equipment cost increases. Furthermore, it is necessary to arrange the camera so that the photographing direction is inclined with respect to the irradiation axis of the laser projector, which complicates the equipment configuration.

  The present invention has been made in view of such a point, and the object of the present invention is to provide a low-cost and simple configuration sealer coating apparatus that can easily inspect the state of a sealer applied to a surface to be coated of a workpiece. Is to provide.

  In order to achieve the above object, the present invention shoots a sealer applied to a coated surface of a work without using a laser projector, and the sealer coating width deviates from a reference value from the captured image. It is characterized by determining whether or not.

That is, in the first invention, the application means for continuously applying the sealer to the application surface of the work, the control means for controlling the application amount of the sealer connected to the application means, and the application to the application surface A camera that shoots a sealer, and the control means sequentially checks the color intensity of each pixel in a direction intersecting the sealer application direction from a predetermined position P at the end of the captured image of the camera, and adjacent color intensity together but extracting two places pixels varying setpoint X ₁ or more as a boundary pixel corresponding to the position of the boundary between the coated sealer and the coated surface to the coated surface, in each pixel other than between the boundary pixels a boundary extraction unit that extracts a pixel which changes adjacent color intensity setting value X ₂ or more as an end pixel corresponding to the end of the work, the sealer coating width w from the number of pixels between the boundary pixels As well as operation, a calculator for calculating the coating position g from the number of pixels between one of the boundary pixel and the end pixel extracted by the boundary extracting portion, the upper limit value W _max and the lower limit value of the sealer coating width w stores the W _min, a storage unit for storing an upper limit value _{G max} and the lower limit value _{G min} of said coating position g, together with the sealer coating width w is equal to or a _{W min} ≦ w ≦ _{W max} And a determination unit that determines whether or not the application position g is G _min ≦ g ≦ G _max , and the control means has the sealer application width w of W _min ≦ w ≦ W _max and If the coating position g is _{G min} ≦ g ≦ _{G max,} while to continue the coating operation by the coating means, when the sealer coating width w is not _{W min} ≦ w ≦ _{W max,} or the coating position If is not G _min ≦ g ≦ G _max, and wherein the stopping the coating operation by the upper Symbol coating means.

In the second invention, in the first invention, the upper term memory unit, a reference value _{W 0} of the sealer coating width w, correction start upper limit W _alpha and correction start lower limit value _{W β (W min <W β} <W _{0 <W α} <W _max) stores, the calculation unit calculates the sealer coating width w at a plurality of locations of sealers applied to the coated surface, the prediction equation from the sealer coating width w computed y = g (t) (t = time, y is the sealer coating width) derive said control means, sealer coating width after a predetermined time T by the prediction equation y w = g (T) is _w <W _β, W α When it is predicted that <w, the coating amount by the coating unit is controlled so that W ₀ = g (T).

  In the first invention, since the sealer coating width can be calculated at an arbitrary position in the image taken without irradiating the laser applied to the sealer coated on the coated surface as disclosed in Patent Document 1, the coated surface The state of the sealer applied to the can be easily inspected. And since the laser projector like patent document 1 is unnecessary, while being able to hold down equipment cost, the freedom degree of arrangement | positioning of a camera increases.

Further , since the application position of the sealer with respect to the application surface of the workpiece can be known from the image taken by the camera, it can be determined whether or not the sealer is applied at the correct position .

In the second invention, when the sealer is continuously applied to the surface to be coated of the workpiece, the amount of the sealer applied by the coating means changes so that the sealer coating width approaches the reference value of the sealer coating width. been coated width of the sealer can always be maintained between the lower limit value W _min and the upper limit value W _max a.

It is a schematic front view of the sealer coating device according to Embodiment 1 of the present invention. It is sectional drawing in the AA of FIG. It is a figure which shows the state which applied the sealer continuously to the press part. FIG. 4 is a schematic diagram in which each pixel is exaggerated by enlarging a portion B in FIG. 3, and shows a flow of sequentially extracting end pixels, boundary pixels, and light / dark boundary line pixels. It is a graph in which the horizontal axis represents time and the vertical axis represents sealer application height. It is a graph with the horizontal axis representing time and the vertical axis representing the sealer coating width. FIG. 5 is a view corresponding to FIG. 4 according to Embodiment 2 of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiment is merely exemplary in nature.
Embodiment 1 of the Invention
1 and 2 show a sealer coating apparatus 1 of the present invention. The sealer coating apparatus 1 continuously applies the sealer C to the surface F2 to be coated of the flange portion F1 of the press part F when the press part F (work) is assembled. The press part F is a general-purpose robot. 11 is held by the tip of the arm portion 11a and the coated surface F2 faces upward.

  The sealer coating apparatus 1 includes a sealer discharger 2 that discharges a sealer C, and the sealer discharger 2 has a discharge nozzle 20 in a posture in which a nozzle opening faces obliquely downward.

  The sealer discharger 2 constitutes a coating means 10 with the general-purpose robot 11, and the discharge nozzle 20 moves the sealer C to the press part F while the general-purpose robot 11 moves the press part F in the horizontal direction. The sealer C is continuously applied in the Z direction on the application surface F2.

  A CCD camera 3 with the photographic lens facing directly below is disposed on the side of the discharge nozzle 20, and the CCD camera 3 applies the sealer C applied to the application surface F2 along the sealer application direction (Z direction). To shoot continuously.

  A pair of LED light sources 4 are arranged on the sides crossing the sealer application direction of the CCD camera 3 with the CCD camera 3 in between, and the LED light sources 4 are disposed on the surface of the sealer C applied to the application surface F2. A pair of light and dark boundary lines 9 are generated in the sealer application direction in the vicinity of the top of the sealer C by irradiating light obliquely from above. The light / dark boundary line on the end portion side of the flange portion F1 is referred to as a light / dark boundary line 9A, and the light / dark boundary line on the opposite end portion of the flange portion F1 is referred to as a light / dark boundary line 9B.

  A controller 5 (control means) is connected to the sealer discharger 2, the CCD camera 3, each LED light source 4 and the general-purpose robot 11.

  The control unit 5 outputs a discharge signal to the sealer discharger 2 to control the discharge amount of the sealer C discharged from the discharge nozzle 20 and outputs a movement signal to the general-purpose robot 11 to output the discharge nozzle. The amount of application of the sealer C is controlled by controlling the moving speed of the press part F with respect to 20.

  Further, as shown in FIGS. 3 and 4, the control unit 5 takes in a photographed image W of the press part F photographed by the CCD camera 3 and applies it to the coated surface F2 based on the photographed image W. The applied state of the sealed sealer C is inspected.

The controller 5 determines the color intensity (R value + B value + G value) of each pixel continuous from the predetermined position P1 at the end of the captured image W of the CCD camera 3 in the direction intersecting the sealer application direction (V direction). examined in order to extract two places pixels that change color intensity adjacent the set value X ₁ or a boundary pixel 6 corresponding to the position of the boundary between the sealer C and the coated surface F2 applied to the coated surface F2 It has a boundary extraction unit 5a. The boundary pixel on the end side of the flange portion F1 is called a boundary pixel 6A, and the boundary pixel on the opposite end side of the flange portion F1 is called a boundary pixel 6B.

Also, the boundary extraction unit 5a, examining the color intensity of each pixel continuous in the V direction from the predetermined position P, and changes the color intensity adjacent to each other in each pixel other than between the boundary pixels 6 set value X ₂ or A pixel is extracted as an end pixel 7 corresponding to the end of the flange portion F1 in the press part F.

Furthermore, the boundary extraction unit 5a, examining the color intensity of each pixel continuous in the V direction from the predetermined position P, and changes the color intensity adjacent to each other in each pixel between the two boundary pixels 6 set value X ₃ or more Pixels are extracted as light / dark boundary line pixels 8 corresponding to the light / dark boundary lines 9. The light / dark boundary line pixel on the end side of the flange portion F1 is called a light / dark boundary line pixel 8A, and the light / dark boundary line pixel on the opposite end side of the flange portion F1 is called a light / dark boundary line pixel 8B.

  The control unit 5 includes a calculation unit 5b that calculates the sealer application width w from the number of pixels between the boundary pixels 6A and 6B extracted by the boundary extraction unit 5a. For example, in the case of FIG. 4, the calculation unit 5 b calculates that the sealer coating width w is 4 mm because the number of pixels between the boundary pixels 6 </ b> A and 6 </ b> B is 8 if one side of a pixel is 0.5 mm. ing.

  The calculation unit 5b calculates the application position g from the number of pixels between the boundary pixel 6A and the end pixel 7 extracted by the boundary extraction unit 5a. For example, in the case of FIG. 4, the calculation unit 5 b has six pixels between the boundary pixel 6 and the end pixel 7 on the end side of the flange portion F1 when one side of one pixel is 0.5 mm. The application position g is calculated as 3 mm. The application position g may be calculated from the number of pixels between the boundary pixel 6B and the end pixel 7.

  Further, the calculation unit 5b calculates the distance s from the number of pixels between the boundary pixel 6A and the light / dark boundary line pixel 8A. For example, in the case of FIG. 4, when the one side of one pixel is 0.5 mm, the arithmetic unit 5b has one pixel between one boundary pixel 6 and one light / dark boundary line pixel 8, and therefore the distance s Is calculated as 0.5 mm. The distance s may be calculated from the number of pixels between the boundary pixel 6B and the light / dark boundary line pixel 8B.

  In addition, the calculation unit 5b calculates the distance s at a plurality of locations of the sealer C applied to the application surface F2, and, as shown in FIG. Regression equation) y = f (t) (t = time, y is sealer coating height).

  Then, as shown in FIG. 6, the calculation unit 5b calculates the sealer application width w at a plurality of locations of the sealer C applied to the application surface F2, and calculates a prediction formula (regression) from each calculated sealer application width w. Expression) y = g (t) (t = time, y is sealer coating width) is derived.

The control unit 5 includes a storage unit 5c that stores an upper limit value W _max and a lower limit value W _min of the sealer application width w in the sealer C applied to the application surface F2.

The storage unit 5c stores an upper limit G _max and a lower limit G _min of the application position g.

In addition, the storage unit 5c includes a sealer application height h to the top of the sealer C applied to the application surface F2 corresponding to the distance s, and an upper limit value _Hmax and a lower limit value of the sealer application height h. H _min is stored.

Furthermore, the storage unit 5c, the reference value _{H 0} of the sealer coating height h, correction start upper limit H _a and the correction start lower limit value _{H b (H min <H b} <H 0 <H a <H max) memory doing.

In addition, the storage unit 5c stores the reference value W ₀ of the sealer application width w, the correction start upper limit value W _α, and the correction start lower limit value W _β (W _min < W _β <W ₀ < W _α <W _max ). I remember it.

The control unit 5 includes a determination unit 5d that determines whether or not the sealer application width w calculated by the calculation unit 5b is W _min ≦ w ≦ W _max .

The determination unit 5d determines whether or not the application position g calculated by the calculation unit 5b is G _min ≦ g ≦ G _max .

In addition, the determination unit 5d determines whether or not the sealer application height h corresponding to the distance s is H _min ≦ h ≦ H _max .

When the sealer coating width w is W _min ≦ w ≦ W _max , the control unit 5 continues the coating operation by the coating unit 10, while the sealer coating width w is W _min ≦ w ≦ W _max. If not, the coating operation by the coating means 10 is stopped.

Further, the control unit 5, when the coating position g is _{G min} ≦ g ≦ _{G max,} while to continue the coating operation by the coating means 10, when the application position g is not _{G min} ≦ g ≦ _{G max} The application work by the application means 10 is also stopped.

Further, when the sealer coating height h is H _min ≦ h ≦ H _max , the control unit 5 continues the coating operation by the coating means 10 while the sealer coating height h is H _min ≦ h ≦. If it is not H _max , the application work by the application means 10 is also stopped.

In addition, as shown in FIG. 5, the control unit 5 predicts that the sealer coating height h = f (T) after a predetermined time T becomes h < H _b , H _a <h according to the prediction formula y. When this is done, the coating amount by the coating means 10 is controlled so that H ₀ = f (T).

Then, the control unit 5, as shown in FIG. 6, sealer coating width after a predetermined time T by the prediction equation y w = g (T) is w _{<W β,} W α <when it is predicted to be w , W ₀ = g (T) so that the coating amount by the coating means 10 is controlled.

  Next, a method for processing the captured image W by the CCD camera 3 will be described.

First, as illustrated in FIG. 4, the control unit 5 sequentially checks the color intensity of each pixel continuous in the V direction intersecting the sealer application direction from the predetermined position P1 at the end of the captured image W. Then, since the color change intensity set value X ₂ or greater between adjacent pixels in the position corresponding to the end portion of the flange portion F1, it extracts the pixel as an end pixel 7.

Next, the color intensity of each pixel continuous in the V direction from the end pixel 7 is examined in order. Then, since the color change intensity set value X ₁ or greater between adjacent pixels corresponding to the boundary between the coated surface F2 of the sealer C and the flange portion F1, it extracts the pixel as a boundary pixel 6A.

Thereafter, the color intensity of each pixel continuing in the V direction from the boundary pixel 6A is examined in order. Then, since the color change intensity set value X ₃ or greater between adjacent pixels in the position corresponding to the light-dark boundary line 9A, it extracts the pixels as dark boundary line pixels 8A.

Thereafter, the color intensity of each pixel continuing in the V direction from the light / dark boundary line pixel 8A is examined in order. Then, since the color change intensity set value X ₃ or greater between adjacent pixels in the position corresponding to the light-dark boundary line 9B, it extracts the pixels as dark boundary line pixels 8B.

Then, the color intensity of each pixel continuous in the V direction from the light / dark boundary line pixel 8B is examined in order. Then, since the color change intensity set value X ₁ or greater between adjacent pixels corresponding to the boundary between the coated surface F2 of the sealer C and the flange portion F1, it extracts the pixel as a boundary pixel 6B.

  Next, the calculation unit 5b of the control unit 5 determines the sealer coating width w, the coating position g, the distance s, and the sealer coating based on the extracted boundary pixels 6A and 6B, the end pixel 7 and the light / dark boundary line pixels 8A and 8B. Calculate the height h.

  Thereafter, the determination unit 5d of the control unit 5 determines whether or not the sealer application width w, the application position g, the distance s, and the sealer application height h are each between an upper limit value and a lower limit value. .

  And the said control part 5 continues the application | coating operation | work by the application means 10, when the said sealer application width w, the application position g, the distance s, and the sealer application height h are located between an upper limit value and a lower limit value, respectively. When the sealer coating width w, the coating position g, the distance s, and the sealer coating height h are not located between the upper limit value and the lower limit value, the coating operation by the coating means 10 is stopped.

  When the coating operation is continued, the other part of the sealer C applied to the application surface F2 is inspected in the same manner as described above. That is, the sealer application width w of the sealer C applied to the application surface F2 by sequentially examining the color intensity of each pixel continuous in the V direction from arbitrary points P2, P3,. It is inspected whether the application position g, the distance s, and the sealer application height h are between the upper limit value and the lower limit value.

  Further, when the sealer application height h and the sealer application width w are calculated at a plurality of locations of the sealer C applied to the application surface F2, the calculation unit 5b calculates the prediction formula y = f from each sealer application height h. (T) (t = time, y is sealer coating height) is derived, and prediction formula y = g (t) (t = time, y is sealer coating width) is derived from each sealer coating width w.

Then, as shown in FIG. 5, the control unit 5 predicts the sealer application height h = f (T) after T seconds set in advance based on the prediction formula y = f (t), and h < H _b , H _a <h, the coating amount is controlled by the coating means 10 so that H ₀ = f (T).

Further, as shown in FIG. 6, the control unit 5 predicts the sealer application width w = g (T) after T seconds set in advance based on the prediction formula w = g (t), and w < W _β , When it is predicted that W _α <w, the coating amount is controlled by the coating means 10 so that W ₀ = g (T).

  As described above, according to the first embodiment of the present invention, the sealer C applied to the application surface F2 is photographed without irradiating the laser slit light as in Patent Document 1, and the sealer application width w is set at an arbitrary position in the image W. Since the calculation can be performed, the state of the sealer C applied to the application surface F2 can be easily inspected. In addition, since the laser projector as in Patent Document 1 is not necessary, the equipment cost can be suppressed and the degree of freedom of arrangement of the CCD camera 3 is increased.

  Further, since the application position of the sealer C with respect to the application surface F2 of the press part F can be known from the image W taken by the CCD camera 3, it can be determined whether or not the sealer C is applied at the correct position.

Further, since not only the sealer application width w but also the sealer application height h can be known from one photographed image W by the CCD camera 3, the sealer application height h and the sealer application width w are applied to the application surface F2 . The approximate cross-sectional shape of the sealer C can be estimated, and it can be accurately determined whether or not the amount of the sealer C applied to the pressed part F is the correct amount.

In addition, when a continuous coating the sealer C in the coated surface F2 of the press part F, the coating amount of sealer C by the coating unit 10 such that the sealer coating height h approaches the reference value H ₀ of the sealer coating height h There so changes can be maintained between the object to be coated always lower limit value applied height h of the applied sealer C in plane F2 H _min and the upper limit value H _max.

Then, when the continuous application of the sealer C in the coated surface F2 of the press part F, so sealer coating width w is the coating amount of the sealer C changes by coating means 10 so as to approach the reference value W ₀ of the sealer coating width w can be maintained between the always lower limit value W _min and the upper limit value W _max the coating width w of sealer C applied to the coated surface F2.
<< Embodiment 2 of the Invention >>
FIG. 6 shows an image obtained by photographing the coated surface F2 of the press part F by the CCD camera 3 of the sealer coating apparatus 1 according to the second embodiment of the present invention. In the second embodiment, the processing method of the captured image W by the control unit 5 is the same as the first embodiment except that the processing method of the captured image W is different from the first embodiment. I will explain only.

  As illustrated in FIG. 6, the control unit 5 according to the second embodiment extracts the light / dark boundary line pixels 8 </ b> A, and then checks the color intensity of pixels separated in the V direction by the number of set pixels (the number of 12 pixels in FIG. 6). The number of set pixels is set so that the next pixel for checking the color intensity is located on the coated surface F2 where the sealer C is not applied.

Thereafter, the control unit 5 sequentially checks the color intensity of each pixel continuous in the anti-V direction. Then, since the color change intensity set value X ₁ or greater between adjacent pixels corresponding to the boundary between the coated surface F2 of the sealer C and the flange portion F1, it extracts the pixel as a boundary pixel 6B.

Thereafter, the control unit 5 sequentially examines the color intensities of pixels that continue further in the anti-V direction from the boundary pixel 6B. Then, since the color change intensity set value X ₃ or greater between adjacent pixels in the position corresponding to the light-dark boundary line 9B, it extracts the pixels as dark boundary line pixels 8B.

  As described above, according to the second embodiment of the present invention, even if a spot that shines due to reflection of illumination or the like occurs near the top of the sealer C applied to the application surface F2, image processing is performed while avoiding the shining spot. Thus, erroneous detection by the control unit 5 can be avoided.

  In Embodiments 1 and 2 of the present invention, the sealer C is continuously applied to the coated surface F2 by moving the press part F while the discharge nozzle 20 is fixed, but the press part F is fixed. The sealer C may be continuously applied to the application surface F2 by moving the discharge nozzle 20 in a state, or the sealer C may be applied continuously to the application surface F2 by simultaneously moving the discharge nozzle 20 and the press part F. It may be.

  In the first and second embodiments of the present invention, the CCD camera 3 is used for shooting the coated surface F2 coated with the sealer C, but a CMOS camera may be used for shooting.

  Further, in Embodiments 1 and 2 of the present invention, the sealer C is photographed by the CCD camera 3 while applying the sealer C to the application surface F2, but the steps of applying the sealer C to the application surface F2, The process of photographing the sealer C applied to the application surface F2 with the CCD camera 3 may be separated.

  In addition, the prediction formulas y = f (t) and y = g (t) are not directly derived from the data of each sealer application height h and each sealer application width w, but the sealer C is determined in the sealer application direction. , Each sealer application height h and each sealer application width w for each of the sections are averaged, and prediction formulas y = f (t) and y = g (t) are calculated using the averaged data. May be derived. As a result, small fluctuations (noise data) in the numerical values of the sealer coating height h and the sealer coating width w caused by pump pulsation or the like in the sealer discharger 2 can be ignored.

  The present invention is suitable for a sealer coating apparatus that continuously applies a sealer to a surface to be coated of a workpiece.

DESCRIPTION OF SYMBOLS 1 Sealer coating device 3 CCD camera 4 LED light source 5 Control part (control means)
5a boundary extraction unit 5b arithmetic unit 5c storage unit 5d determination unit 6 boundary pixel 7 end pixel 8 light / dark boundary line pixel 9 light / dark boundary line 10 coating means C sealer F press part (work)
F2 Surface to be coated W Photographed image w Sealer application width h Sealer application height s Distance g Application position

Claims (2)

Application means for continuously applying a sealer to the surface to be coated of the workpiece;
Control means connected to the application means for controlling the application amount of the sealer;
A camera for photographing the sealer applied to the application surface,
The control means checks the color intensity of each pixel continuous in a direction intersecting the sealer coating direction from a predetermined position P of the end portion in the captured image of the camera in the order, the pixels that change color intensity adjacent the set value X ₁ or more Are extracted as two boundary pixels corresponding to the position of the boundary between the sealer coated on the coated surface and the coated surface, and the adjacent color intensity is set to the set value X _{2 in} each pixel other than between the boundary pixels. A boundary extraction unit that extracts the pixels that change as edge pixels corresponding to the edge of the workpiece ;
A calculation unit that calculates the sealer application width w from the number of pixels between the boundary pixels and calculates the application position g from the number of pixels between one boundary pixel and the end pixel extracted by the boundary extraction unit ;
A storage unit that stores the upper limit value W _max and the lower limit value W _min of the sealer application width w, and stores the upper limit value G _max and the lower limit value G _min of the application position g ;
Together with the sealer coating width w is equal to or a _{W min} ≦ w ≦ _{W max,} the coating position g is provided with a determination section for determining whether or not a _{G min} ≦ g ≦ _{G max,}
When the sealer coating width w is W _min ≦ w ≦ W _max and the coating position g is G _min ≦ g ≦ G _max , the control unit continues the coating operation by the coating unit, If sealer coating width w is not _{W min} ≦ w ≦ _{W max,} or if the coating position g is not _{G min} ≦ g ≦ _{G max,} sealer coating apparatus characterized by stopping the coating operation by the upper Symbol coating means . The sealer coating apparatus according to claim 1 ,
The storage unit stores a reference value W ₀ , a correction start upper limit value W _α and a correction start lower limit value W _β (W _min < W _β <W ₀ < W _α <W _max ) for the sealer application width w,
The calculation unit calculates a sealer application width w at a plurality of locations of the sealer applied to the surface to be applied, and predicts y = g (t) (t = time, y is a sealer) from each calculated sealer application width w Application width),
Said control means, sealer coating width after a predetermined time T by the prediction equation y w = g (T) is w _{<W β,} W α <when it is predicted to be _w, W 0 = a g (T) A sealer coating apparatus for controlling the coating amount by the coating means.