JPH06148090A - Painting inspection information analyzer - Google Patents

Abstract

PURPOSE:To facilitate analysis of correlation by unifying processing information of facilities and quality information of painted film in painting inspection information analyzer for analyzing correlation between processing conditions of painting and painting quality under the conditions. CONSTITUTION:Processing conditions of facilities installed in an intercoating step (second step), a finish coating step (fourth step) and a drying step (fifth step) are detected, and stored in a predetermined format in a measuring data base 5. An inspection result of a painted film quality inspecting unit for inspecting a quality of a painted film is stored as quality information in a predetermined format in the base 5. Data of the base 5 is transferred to a statistical processor 6 and a statistically processing computer 7. The processor 6 and the computer 7 connect the quality information of the film and processing conditions for generating the quality, and statistically process it.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coating inspection information analyzing apparatus, and more particularly to a coating inspection information analyzing apparatus for analyzing the correlation between a plurality of conditions in a coating process and coating quality under the conditions.

[0002]

2. Description of the Related Art Painting of automobile bodies requires not only excellent corrosion resistance and durability but also good aesthetics. For this reason, the coating process is multi-processed, such as an undercoating process by electrodeposition coating, an intermediate coating process for smoothing the undercoating surface, and an external coating process for ensuring aesthetics and durability. There is.

The equipment in each of these processes is set to the coating conditions empirically required to obtain a good coating film, and each equipment is strictly controlled so that the conditions do not deviate from the permissible range. It is managed. Also,
In order to obtain a good coating film, various measures have been taken in addition to the control of equipment conditions. For example, many measures have been taken to prevent adhesion of dust and the like during transportation between processes and its removal method. .

However, as a practical matter, it is impossible to perfect the coating quality of all car bodies, and it is necessary to require the operator to completely find all defects by visual inspection. It will impose extremely heavy labor. On the other hand, the coating quality defect is a defect in the appearance of the automobile and is one of the defects that the user cannot easily overlook, and therefore cannot be overlooked and shipped as it is.

Therefore, conventionally, in the final step of the coating process, for example, a coating film quality inspection device described in Japanese Patent Application Laid-Open No. 1-210806 is installed to limit the defective portion, If necessary, the operator will rework.

The apparatus described in the above publication scans the surface of the vehicle body by a predetermined method, and the coated surface has a diameter of 1
When a protrusion of about 3 mm is detected, it is determined as a defect and the device prints out the existence position data of "butsu" for each vehicle. Therefore, the worker in charge of reworking can easily perform the work of removing "bugs" based on this data.

[0007]

However, although the above-described conventional process control method can prevent the defective vehicle from being finally shipped, it is based on the data obtained therefrom. It is difficult to analyze the cause of "bugs".

This is because a plurality of vehicles are mixedly mounted on the vehicle body painting line for the sake of production, each vehicle is painted in a plurality of colors, and the equipment installed for each process requires cost and productivity. For the above reason, there are cases where the operation must be started before the processing conditions stabilize, and the fluctuations occur within the range of the set conditions.

That is, when trying to analyze the correlation between each processing condition and the coating quality based on it from the data obtained by the conventional process control, the data printed out from the coating quality inspection device is used. It is necessary to classify the products by vehicle type and color, and compare the results with the processing conditions at the time of painting the vehicle body of the equipment arranged for each process, which requires a huge amount of time and labor.

For this reason, conventionally, it has been considered that there is some correlation between the processing conditions of each equipment and the coating quality in the painting process of the car body of an automobile, but a systematic analysis is performed. Couldn't do enough. Therefore, the processing condition of each equipment is set empirically for each equipment, and it takes a lot of man-hours to set the condition, and when an abnormality occurs, it may take a long time to find the cause. Had a problem.

The present invention has been made in view of the above points, and systematically processes the processing information in each facility and the coating film quality information under the conditions, and the correlation between them can be easily analyzed. The purpose is to provide a coating inspection information analysis device.

[0012]

FIG. 1 shows a principle diagram of a coating inspection information analyzing apparatus for solving the above problems. In FIG. 1, reference numeral 1 indicates a processing condition detecting means for detecting processing conditions of equipment installed in each coating process. Reference numeral 2 indicates a coating film quality inspection means for inspecting the quality of the coating film on the vehicle body.

The measurement database 3 stores the processing information detected by the processing condition detecting means and the quality information regarding the coating quality detected by the coating quality inspection means in a predetermined format. Then, the statistical processing means 4 performs statistical processing on the processing information and the quality information stored in the measurement database, and analyzes the correlation existing between the processing conditions and the coating film quality.

[0014]

In the coating inspection information analyzing apparatus described above, the processing condition detecting means 1 detects the processing conditions in each facility when the vehicle passes through each process, and supplies the processing information to the measurement database 3. The coating film quality inspection means 2 inspects the coating film surface of the painted vehicle body to detect what kind of defect occurs in which part and supplies the quality information to the measurement database 3.

The measurement database 3 stores the processing information supplied from the processing condition detecting means 1 and the quality information supplied from the coating film quality inspecting means 2 in association with each vehicle body. Then, the statistical processing means 4 uses the measurement database 3
The processing information and the quality information stored therein are statistically processed, and the correlation between each processing condition and the coating quality is analyzed.

[0016]

FIG. 2 is a conceptual diagram of an embodiment of a coating inspection information analyzing apparatus according to the present invention. Hereinafter, the configuration of the present embodiment will be described with reference to the figure. Prior to that, the flow of the vehicle body painting process will be described using the flow chart shown in FIG.

FIG. 3 is a flow chart showing an outline of a general flow in painting a vehicle body. The coating process of the vehicle body can be roughly classified into three types: undercoating, intermediate coating, and topcoating, and a coating film is formed by passing through these processes.

First, in the first step, the undercoat of the vehicle body is applied. This undercoating is performed in order to hide the irregularities of the steel plate forming the vehicle body to form a smooth surface, improve the adhesion between the coating film and the base material, and secure the rust preventive effect. In order to ensure a uniform coating surface on a vehicle body with a complicated shape, this undercoating is widely used by electrodeposition coating, in which a charged vehicle body is dipped in an electrolyte paint as shown in FIG. Has been.

In the second step, intermediate coating is performed. The intermediate coating is coating for smoothing the surface of the coating film formed by the undercoat coating, and is performed by spraying the coating material. When this intermediate coating is completed, next water polishing is performed (third step). This water polishing is a polishing process for the vehicle body to obtain a complete groundwork before the next overcoating.

After the rust prevention and the surface smoothing treatment are carried out in this manner, the vehicle body is subjected to the final coating, that is, the top coating (fourth step). This top coating is also carried out by spraying in the same manner as the above intermediate coating. A coating device capable of spraying paints of a plurality of colors is installed in the zone of the overcoating process, and a paint of a predetermined color selected according to the production instruction content of the vehicle body flowing through the coating line is sprayed.

At this time, conventionally, as illustrated in the fourth step in FIG. 3, the overcoating coating device outputs processing conditions such as paint temperature and paint discharge amount to a monitor. Then, when the processing conditions become abnormal, measures such as stopping are automatically taken. The operator can determine whether the coating device is functioning normally based on the processing information displayed on the monitor, and in the event of an abnormality, the necessary recovery work can be performed efficiently based on that information. it can.

After finishing the overcoating, the coating film is dried to cure the coating film (fifth step). That is, in order to evaporate the volatile components contained in the coating material and accelerate the curing reaction of the coating material to obtain a coating film with high hardness in a short time, the coating material is left in a drying oven at a high temperature (about 120 to 160 ° C) for a predetermined time. It Here, the drying furnace also outputs such information to the monitor in order to inform the operator of the processing conditions such as the temperature and humidity of the drying furnace, as in the case of the top coater.

A car body having a large heat capacity is successively loaded into the drying furnace. For this reason, it is difficult to maintain the temperature inside the furnace at a constant value, and normally, a configuration is adopted in which the temperature inside the furnace is maintained within a predetermined range by feedback control.

When the painting of the vehicle body is completed in this way,
It is inspected whether the formed coating film is normal (6th
Process). In this inspection, for example, "floating" of the coating film due to poor adhesion of the paint, adhesion of foreign matter such as dust or dirt during transfer between coating processes, and mixing of foreign matter into the paint, diameter of 1 to 3 mm
Some degree of protrusions (so-called “bugs”) and the like are judged as defects.

Conventionally, in this inspection step, an inspection apparatus has been introduced for scanning the surface of the coating film to detect these defects. This inspection device automatically inspects for the presence of defects, and if there is a defect, prints out information about which part on the vehicle body the defect occurs (see the check sheet shown in FIG. 4). . Then, the worker in charge of the rework repairs the coating film on the basis of the printed-out defect information (marked with X in FIG. 4) (Seventh)
Process).

As described above, since the inspection device is introduced to inspect the quality of the coating film, the operator can know the defective portion without needing to inspect the front surface of the vehicle body by himself, and The burden is reduced. In addition, small "bugs" and slight "floats" are not overlooked, and as a result, the coating quality at the time of shipping is improved.

Incidentally, in FIG. 3, the monitor output status of the processing conditions of each equipment is described only for the fourth to sixth steps for convenience, but it is installed in the first to third steps. The equipment also outputs various kinds of processing information to the monitor in the same manner as the equipment installed in the fourth to sixth steps.

In this embodiment, as shown in FIG.
The intermediate coating process (second process), the top coating process (fourth process), and the drying process (fifth process) are selected from the above processes, and the processing information in each process is transferred to the measurement database 5. The equipment installed in each process incorporates a processing condition detecting device corresponding to the above-mentioned processing condition detecting means.

In addition to the processing information, the measurement database 5 is provided with the inspection result of the coating film quality, that is, the coating film quality information, from the coating film quality inspection device installed in the inspection process (sixth process). Hereinafter, the configuration and inspection items of the coating film quality inspection apparatus according to the present embodiment will be described with reference to FIGS.

FIG. 5 is a perspective view showing the structure of the coating quality inspection device used in this embodiment. In FIG. 5, reference numeral 11 indicates a vehicle body carried into the coating quality inspection device 10 by the conveyor 12. Reference numeral 13 denotes a vehicle body number reading device, which reads the vehicle body number given to each vehicle body when the vehicle body 11 is carried into the coating quality inspection device 10.

Information such as coating color and model for each vehicle body number is provided to each facility installed in the coating line by a production instruction system (not shown). This information is supplied from the main body of the production instruction system to each facility installed in the coating line through the cable 14 for the production instruction system. Then, each facility determines the processing content to be applied to the carried-in vehicle body by considering the production instruction information and the vehicle body number read by the vehicle body number reading device installed for each facility.

In the coating quality inspection device 10, it is necessary to grasp the coating film quality for each vehicle body number, and the vehicle body number read by the vehicle body number reading device 13 is used to inspect the coating film quality via the production instruction system cable 14. Is supplied to the counting computer 15 that counts the results.

The coating film surface of the vehicle body 11 is inspected by the coating film sensor 1
This is performed by scanning the surface of the vehicle body 11 with the reference numeral 6.
The coating film sensor 16 is connected to a robot 17.
Further, the robot 17 is connected to the robot moving beam 18, and the coating film sensor 16 can be freely moved according to the shape of the vehicle body 11.

Then, the robot control device 19 determines the model of the vehicle body 11 based on the vehicle body read by the vehicle body number reading device 13, and controls the robot 4 according to a preset program according to the model. Therefore, the coating film sensor 16 always scans the coating film surface with an optimum operation for each vehicle body, even if a plurality of vehicle bodies 11 of different types are mixed on the coating line. In FIG. 5, reference numeral 20 indicates a control panel of the robot controller 19.

FIG. 6 is a front sectional view showing the structure of the coating film sensor 16. The principle of detecting defects such as "bugs" generated on the coating film will be described below with reference to FIG.

As shown in FIG. 6, in the coating film sensor 16, a vertical stripe pattern is projected on the coating film 32 by the light source 30 and the vertical stripe grid 31, and the projected vertical stripe pattern is imaged by the CCD camera 33. Then, the image thus captured is processed by the microcomputer 34 that constitutes the image processing device 21 in FIG.

The microcomputer 34 binarizes the image pickup signal supplied from the CCD camera 33 by comparing it with a predetermined reference value to reproduce the vertical stripe pattern formed on the surface of the coating film. At this time, if there is a defective portion such as "bugs" on the surface of the coating film, the vertical stripe pattern projected on that portion is distorted.

Therefore, the microcomputer 34 searches for a portion where the vertical stripe pattern is distorted, and when the distortion is detected, which portion on the vehicle body 11 the distortion exists,
In addition, a calculation is performed as to how many pixels of the CCD camera the distortion corresponds to. Then, the calculation result is transmitted to the counting computer 15 shown in FIG.

FIG. 7 is a diagram showing a format in which the quality information of the coating film supplied from the coating film sensor 16 when the coating film quality of the vehicle body 11 is inspected is stored in the totaling computer 15.

As shown in FIG. 7, the coating film quality information is organized and stored for each vehicle number. At this time, as the quality information, data about how many defects are present in each inspection zone obtained by dividing the vehicle body 11 into a predetermined size and data about the size of the defect are stored.

The microcomputer 15 shown in FIG.
The printer 22 for collecting the quality information in such a format and printing out the check sheet shown in FIG. 4 is driven, and the quality information is supplied to the measurement database 5 shown in FIG.

FIG. 8 shows a format of processing information supplied from the equipment installed in each process to the measurement database 5. The processing condition detection means incorporated in each facility is shown in FIG.
Two types of processing information as shown in (B) are supplied to the measurement database 5.

One format is data organized by vehicle body number as shown in FIG. 8A, and is composed of data on the time when the vehicle body flowing through the coating line has passed each process. The other format is data in which the processing conditions of each facility are arranged on the basis of the date and time as shown in FIG. 8B, and is composed of data such as the temperature of the drying oven, the paint temperature, and the paint discharge amount at each time. It

Therefore, if the vehicle body number is designated for the data in the format shown in FIGS. 7 and 8 and the data in the format shown in FIG. 8B is searched at the time when each process is passed, It is possible to combine the equipment conditions at the time of painting with the coating quality. As described above, according to the present embodiment, it is possible to easily unify the processing condition and the quality condition by using the data which has conventionally been used for the process control independent for each process.

In FIG. 2, reference numerals 6 and 7 represent a statistical processing device and a statistical processing computer, respectively, which constitute the statistical processing means 4 described above.

The statistical processing device 6 and the statistical processing computer 7 statistically process the processing information and the quality information stored in the measurement database 5 in the above-described format, thereby processing the processing conditions and the coating film quality. This is a part for analyzing the correlation between the two.

Below, an example of the statistical processing performed in this embodiment and the analysis results in the processing will be described with reference to FIGS.

FIG. 9 shows the result of statistical processing focusing on the correlation between the number of "bugs" generated in the vehicle body 11 and the variation in work style. Here, the change in the work form refers to a shift between daytime work (hereinafter referred to as day shift) and night work (hereinafter referred to as night shift).

For example, it is assumed that the workers are divided into two groups, and a day shift and a night shift are alternately performed for one week. In this case, if the work style continues during the day shift or night shift, the physical condition of the worker adapts to the work style, so that it is generally said that the product quality tends to be stable. On the contrary, it is said that immediately after the work style is changed, the physical condition of the worker is not sufficiently adapted to the work style, and thus the number of defects is likely to temporarily increase.

FIG. 9 shows the results obtained by capturing this tendency as data. The respective data are the average value and standard deviation of "butsu" occurring on the last day and the first day of the day shift, the last day of the night shift, and the first day of the night shift. The average value and the standard deviation of the generated "bugs" are shown. From this result, it can be inferred that there is a correlation between the change in the work form and the coating quality, and it is understood that the difference itself between the day shift and the night shift has some influence.

FIG. 10 shows the result of summing up the number of "bugs" generated by month. As shown in FIG. 10, it can be seen that the number of “bugs” generated is not constant throughout the year. In other words, it can be inferred that changes in the external environment such as temperature and humidity have some influence on the occurrence of "butsu".

Further, FIG. 11 shows a bar chart in which defects occurring on one day are tabulated by location. This result indicates that defects are concentrated on a specific portion of the vehicle body. Therefore, it can be inferred that some reason exists in the coating device or that foreign matter such as dust or the like is likely to adhere to a specific portion during transportation.

FIG. 12 is a scatter diagram prepared for the purpose of investigating the relationship between the average size and the drying oven temperature, focusing on the temperature of the drying oven as a processing condition, averaging the sizes of defects generated for each vehicle body. Show. As a result, it can be understood that the defect size tends to decrease as the drying oven temperature increases.

As described above, according to this embodiment, the correlation between the processing conditions and the coating quality can be easily found.
Therefore, it becomes possible to systematically analyze the processing conditions that have been set empirically in the past, and to set the processing conditions with fewer defects in the future. In addition, since it is possible to immediately and accurately grasp the content of the defect, it is possible to immediately investigate the cause of the sudden abnormality, and it is possible to dramatically reduce the time required for abnormality treatment. Become.

In the above embodiment, only the correlation between one processing condition and the coating quality is analyzed, but the present invention is not limited to this. A configuration may be employed in which the multiple correlation is observed by focusing on the temperature and the discharge amount of the paint. Further, the condition of the equipment installed in each process may be set to a predetermined level to positively find a factor having a difference.

Further, in the above embodiment, the object of analysis is limited to the correlation between the processing conditions in the painting process and the coating film quality, that is, the product quality, but the processing conditions in multiple processes may have some influence on the product quality. If given to
For example, it can be applied to analysis of heat treatment process of steel materials, manufacturing process of semiconductors, and the like.

[0057]

As described above, according to the present invention, it becomes possible to unify the quality information regarding the coating film quality of the vehicle body and the processing conditions of each equipment when the coating film is formed.
It becomes possible to easily find a correlation between processing conditions and coating film quality, which was virtually impossible.

Therefore, it becomes easy to analyze the cause of defects in the coating process, and it becomes possible to design a process with few defects. Moreover, when a sudden abnormality occurs, the time required for investigating the cause is groundbreaking. It has a feature that it is possible to shorten the time required for the abnormal treatment.

[Brief description of drawings]

FIG. 1 is a principle diagram of a coating inspection information analyzing apparatus according to the present invention.

FIG. 2 is a configuration diagram of an embodiment of a coating inspection information analyzing apparatus according to the present invention.

FIG. 3 is a diagram for explaining a vehicle body coating process.

FIG. 4 is a diagram showing an example of a check sheet printed out by the coating film quality inspection device used in this embodiment.

FIG. 5 is a perspective view showing a configuration of a coating film quality inspection device used in this embodiment.

FIG. 6 is a diagram for explaining the operation of the coating film quality inspection device used in this embodiment.

FIG. 7 is a chart showing a data format of coating film quality which is incorporated by the coating film quality inspection apparatus used in this embodiment.

FIG. 8 is a chart showing the format of data provided to the measurement database from the equipment installed in each process in this example.

FIG. 9 is a chart showing a result of totaling the number of defects generated in a coating film before and after a change in the working style of an operator.

FIG. 10 is a chart showing a result of totaling the number of defects generated in a coating film by month.

FIG. 11 is a chart in which the number of defects generated in one day is tabulated by totaling each of the generated regions.

FIG. 12 is a scatter diagram focusing on the relationship between the size of defects generated in a coating film and the drying oven temperature.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Processing condition detection means 2 Coating quality inspection means 3,5 Measurement database 4 Statistical processing means 6 Statistical processing device 7 Statistical processing computer 11 Vehicle body 13 Body number reading device 15 Totaling computer 16 Coating film sensor 21 Image processing device

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hiroyuki Oishi 1 Toyota-cho, Toyota-shi, Aichi Toyota Motor Co., Ltd.

Claims (1)

[Claims] 1. A processing condition detecting means for detecting processing conditions of equipment installed in a coating process, a coating quality inspection means for inspecting coating quality, and processing information detected by the processing condition detecting means. A measurement database that stores quality information relating to the coating film quality detected by the coating film quality inspection means in a predetermined format; and statistical processing is added to the processing information and the quality information stored in the measurement database, A coating inspection information analysis device comprising: statistical processing means for analyzing the correlation between processing conditions and coating film quality.