JPH07323244A - Apparatus for calculating thickness distribution of coating film - Google Patents

Abstract

PURPOSE:To easily grasp a film thickness distribution approximate to the film thickness distribution in an actual coating application by a coating robot without carrying out the actual coating work by the coating robot. CONSTITUTION:The table data of the film thickness value distribution which is to be referred to and is stored in a film thickness distribution storage means 14 in accordance with the coating conditions for the purpose of simulation to be set is selected by a display point generating means 24. The coating film thickness distribution of the selected table data is caused in the form of the display points of the number corresponding to the film thickness on the virtual plane in front of the coating material spraying direction. The display points generated on the virtual plane are projected to the surface to be coated on the simulation by a display point projecting means 26, by which the film thickness distribution is easily grasped from the scattering state of the display points.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coating film thickness distribution calculating device capable of easily visually or numerically grasping a coating film thickness distribution without actually performing a coating operation by a coating robot.

[0002]

2. Description of the Related Art Since the coating quality of a vehicle body has a great influence on the durability of the vehicle, it is required to maintain the film thickness of the coating on the coated surface at a predetermined value.
In automatic painting by the painting robot of the vehicle body, if the coating conditions are always constant, the film thickness will change depending on the shape of the surface to be coated, so the coating conditions should be changed sequentially according to the shape of the surface to be coated. Changing. Conventionally, in order to make the coating thickness distribution on the coating surface constant, after performing rough teaching only on the movement trajectory of the coating robot by simulation, test coating (fine teaching) was performed many times by the actual coating robot. The coating conditions at each teaching position of the coating robot were determined by trial and error.

Off-line programming of painting robots using color graphics technology is known as a prior art document relating to painting techniques by painting robots (author: Alexander Klein, author: Computer & Automation Institute of Technology, Hungarian Academy of Sciences). . In this document, by obtaining the trajectory of the robot tip close to the optimum condition, while minimizing the paint loss,
It is described that a good uniform coated surface is obtained.

[0004]

However, when the coating conditions at each teaching position of the coating robot are determined by trial and error as in the conventional case by actually performing test coating many times, it is very difficult to create an operation program for the coating robot. It will take man-hours. In addition, a large amount of paint and works to be used for the test coating are required, and the material cost becomes large.

In the case of off-line programming of a coating robot using the above-mentioned color graphics technology,
Considering that the pattern shape of the applied paint is conical, from the paint conditions (spray gun performance, paint usage, gun distance, gun feed speed) initially set assuming a geometric model. Since the film thickness value of the coated part is calculated by simulation, only the theoretical film thickness value can be obtained. In the actual coating work, the amount of coating material changes due to changes in the shape of the surface to be coated, etc., so the actual film thickness differs from the theoretical value, and there is the problem that the data will not be suitable for the coating site.

Further, in the case of off-line programming of a coating robot using color graphics technology, the film thickness distribution state is visualized by the change in color. Therefore, the surface to be coated is divided into several grids. , It is necessary to display a color proportional to the film thickness value in that unit. Therefore, there is a problem in that the data for grid division must be provided, the amount of data is greatly increased, and the response of data processing is deteriorated.

The present invention provides a coating film thickness distribution calculating device capable of easily grasping a film thickness distribution close to an actual coating work by a coating robot without performing an actual painting work by a coating robot. With the goal.

[0008]

A coating film thickness distribution calculating device according to the present invention for achieving this object is as follows. (1) A storage means for storing the shape of the coating robot, a work to be coated, and teaching work data, and a film thickness distribution storage means for storing the coating film thickness distribution for a number of coating conditions obtained by a coating experiment as table data. When the coating conditions to be simulated are set, table data to be referenced corresponding to the set coating conditions is selected from the table data, and the coating film thickness distribution of the selected table data is displayed on the virtual surface in front of the paint spraying direction. Display point generating means for generating the number of display points according to the film thickness, and display point projecting means for projecting the display points on the virtual surface onto the coated surface of the work. Paint film thickness distribution calculator. (2) The film thickness value calculating means for calculating the film thickness value at an arbitrary portion of the surface to be coated based on the density of the display points projected on the surface to be coated by the display point projecting means. Paint film thickness distribution calculator. (3) Film thickness distribution storage means for storing the coating film thickness distribution for the coating conditions obtained by the coating experiment as table data, and storage means for setting the coating direction vector for each interpolation point based on the teaching position of the coating gun. , Interpolating from a relationship between the designated portion and the sandwiched surface, and a sandwiching surface determining means for determining a sandwiched surface that sandwiches an arbitrary designated portion of the surface to be painted among virtual surfaces created by the coating direction vector of the interpolation point. The position of the coating gun between points is calculated, and the film thickness value at any designated portion of the surface to be coated is calculated based on the position of the coating gun, the designated portion, and the coating thickness distribution of the table data for the coating conditions to be simulated. A film thickness value calculating means,
A coating film thickness distribution calculation device characterized by being equipped with.

[0009]

In the coating film thickness distribution calculating device of the above (1), the shape of the coating robot, the work to be coated, and the teaching work data necessary for the simulation stored in the storage means are read. When the coating condition to be simulated is set in the display point generating means, the table data corresponding to the simulation coating condition is selected from the table data stored in the film thickness distribution storage means. The display point generating means generates the coating film thickness distribution of the selected table data in the form of a number of display points corresponding to the film thickness on the virtual surface set forward of the paint spraying direction. Since the display point projection means projects the display point on the virtual surface onto the surface to be painted,
It is possible to easily understand the film thickness distribution from the scattered state of the display points on the surface to be coated. As the film thickness distribution made into table data, since the raw data actually obtained by the coating experiment is used, it is possible to grasp the film thickness distribution similar to the actual coating work by the coating robot. Therefore, it is not necessary to perform the trial painting with the actual painting robot many times and determine the painting conditions by trial and error, and the work amount for creating the actual painting robot operation program (fine teaching) can be significantly reduced. Become. (2) In the coating film thickness distribution computing device of (2) above,
Since the film thickness value calculating means calculates the film thickness value at an arbitrary part based on the point density of the display points projected on the surface to be coated by the display point projecting means, the film thickness distribution can be easily grasped numerically. It becomes possible.

(3) In the coating film thickness distribution computing device of the above (3), the coating direction vector is set in the storage means for each interpolation point based on the teaching position of the coating gun. When the user designates an arbitrary designated portion whose film thickness value is to be known on the surface to be coated, the sandwiching surface determining means determines the sandwiching surface that sandwiches the designated portion of the virtual surface created by the coating direction vector of the interpolation points. It Next, the position of the coating gun between the interpolation points is calculated by the film thickness value calculating means from the relationship between the designated portion and the sandwiched surface. When the position of the coating gun is calculated, the film thickness value calculation means calculates the specified portion by the coating experiment from the relationship between the position of the coating gun, the designated portion, and the coating thickness distribution of the table data for the coating condition to be simulated. It is possible to grasp which part of the coating film thickness distribution corresponds to, and the film thickness value of the designated part is calculated. Since the film thickness distribution made into table data stored in the film thickness value distribution storage means is the raw data actually obtained by the coating experiment, the film thickness value close to the actual coating work by the coating robot can be grasped. Is possible.

[0011]

1 to 8 show a first embodiment of the present invention, and FIGS. 9 to 20 show a second embodiment of the present invention. CAD (Computer Aided Design)
1 shows a coating film thickness distribution calculation display device 1 constructed on a system, which has a configuration common to the first and second embodiments. The coating film thickness distribution calculation display device 1 has a computer (CPU) 10. A hard disk 12, a display 15, and a keyboard 16 are connected to the computer 10. A display 20 is also connected to the computer 10 via a graphics controller 18. A hard copy 22 for printing out image contents is connected to the display 20. A mouse 23 is connected to the graphics controller 18.

First Embodiment As shown in FIG. 1, the computer 10 has a display point generation means 24, a display point projection means 26, and a film thickness value calculation means 2.
8 is formed. The display point generation means 24, the display point projection means 26, and the film thickness value calculation means 28 are constituted by programs stored in the computer 10. A storage unit 13 and a film thickness distribution storage unit 14 are formed on the hard disk 12. The storage means 13 stores the shape of the painting robot for simulation (algorithm for determining the posture of the robot), the work to be painted (eg, design data of the vehicle bumper), teaching work data (painting position, painting speed, painting pattern width, etc.). Data) is stored. The film thickness distribution storage means 14 stores table data in which coating film thickness distributions are obtained for a large number of coating conditions by a coating experiment. In the film thickness measurement in the coating experiment, the film thickness after baking is measured. The table data from the film thickness distribution storage means 14 is input to the display point generation means 24.
To the display point generating means 24, for example, a painting condition to be simulated is input via the keyboard 16.

The coating conditions of the table data stored in the film thickness distribution storage means 14 are, for example, the paint discharge amount, the gun distance, the electrostatic coating voltage, and the like. The coating in the coating experiment is performed by one-shot coating (for example, 0.04 seconds = 1 interpolation). That is, since the coating robot changes the trajectory every 0.04 seconds, it is necessary to sequentially change the coating conditions accordingly, and therefore the coating experiment is performed by one shot coating. In the coating experiment, the film thickness of the coating is set to table data with values at a distance 2nl (n = 0, 1, 2, 3 ...) From the ejection center in the radial direction.

The display point generating means 24, based on the simulation coating conditions set via the keyboard 16,
The table data to be referred to is selected from the table data stored in the film thickness distribution storage means 14. As shown in FIGS. 2 and 3, the display point generating means 24 is a virtual surface 50 set to be separated from the tip of the coating gun 56 in the simulation by the same distance A as the gun distance in the coating experiment in the front direction of the coating spray. In addition, it has a function of randomly generating the coating film thickness distribution of the selected table data in the form of the number of display points 52 corresponding to the film thickness. As shown in FIG. 2, the display point projection means 26 causes the spray position of the paint T (the tip of the coating gun 56) on the simulation and the virtual surface 50 to be displayed.
A function of calculating the vector 58 in the direction connecting each of the display points 52 generated above and projecting the display points 52 on the virtual surface 50 onto the painted surface 54 of the simulation work existing in the vector direction is provided. Have In this embodiment,
The virtual surface 50 is perpendicular to the axis of the coating gun 56, but the virtual surface 50 may be inclined with respect to the axis of the coating gun 56. In this case, it is desirable that the surface to be coated in the coating experiment is also inclined by the same amount with respect to the axis of the coating gun that ejects the coating, but if the inclination is slight, correct the film thickness value measured at a right angle. It is also possible to deal with.

The display 20 as a display means has a function of displaying the display point 52 projected on the surface 54 to be coated by the display point projection means 26 on the screen. A film thickness value calculation means 28 is connected to the point projection means 26. The film thickness value calculating means 28 has a function of calculating a film thickness value at an arbitrary portion of the surface 54 to be coated, based on the point density of the display points 52 projected on the surface 54 to be coated by the display point projecting means 26. ing. The display 20 as display means also has a function of displaying the film thickness value calculated by the film thickness value calculating means 28 on the screen.

Next, the operation of the coating film thickness distribution computing device according to the first embodiment will be described. Figure 5
The processing procedure of the film thickness display simulation in the coating film thickness distribution computing device 1 is shown. In step 100 of FIG. 5, necessary data is read into the work area in the RAM of the computer 10. The necessary data are the shape of the painting robot, the work to be painted, and teaching work data which are already stored in the storage means 13 of the hard disk 12. When the processing of step 100 is completed,
Proceeding to step 110, the paint condition for simulation is displayed by the display point generating means 24 of FIG.
Entered in.

When the simulation coating conditions are set, the process proceeds to step 120, where the coating robot operation simulation on the screen of the display 20 is started and the coating robot performs the coating work on the screen. The trajectory of the painting robot is generated by the above-mentioned 1 interpolation (0.04 seconds).
It is performed every time, and by making it continuous, it is possible to perform continuous coating simulation, and it is possible to grasp the film thickness distribution on the screen. When the trajectory of the painting robot in one interpolation is completed, the process proceeds to step 130, and the film thickness display process on the screen at this position is performed.

FIG. 6 shows the film thickness display processing in step 130. In step 130-1 of FIG. 6, table data to be referred to in the hard disk 12 is selected by the display point generating means 24 on the basis of the simulation painting condition input from the keyboard 16.
Next, proceeding to step 130-2, the film thickness value at the radius 2nl (n = 0, 1, 2, ...) From the center of the virtual surface 50 is read based on the film thickness value distribution of the selected table data. When the process of step 130-2 ends, the process proceeds to step 130-8, and it is determined whether or not the generation of the display point 52 proportional to the film thickness value has ended. here,
If the generation of the display point 52 is completed, the process proceeds to the next process, and the process in step 140 of FIG. 5 is performed.

At step 130-8, the display point 52 is displayed.
If it is determined that the occurrence of the above has not ended, the process proceeds to step 130-3, and the radius r and the angle θ
To generate a display point 52 proportional to the film thickness value. The range of the radius r is (2n-1) l to (2n + 1) l
Is. Here, n = 1, 2, 3, ... And when n = 0, the range of the radius r is 0 to 1. When n = 1, the radius r ranges from 1 to 3l, and when n = 2, the radius r ranges from 3l to 5
It becomes l. The range of the angle θ is 0 to 360 °.
In this embodiment, as shown in FIG.
When μ, the number of display points proportional to 20 is generated, and when the film thickness is 15 μ, the number of display points proportional to 15 is generated.

In step 130-3, the number of display points 52 proportional to the film thickness value are randomly generated on the virtual surface 50 because the display points 52 are scattered uniformly. Further, in the present embodiment, when n = 1, the film thickness of the table data at the radius r = 2l is 15μ, so that the number of points proportional to 15 is generated, but the display range area (l to 3l) is generated. ) Is 8 times that in the case of n = 0, so that actually 15a × 8 = 120a (a is a proportional constant) display points 52 are displayed.

When the processing of step 130-3 is completed,
Proceeding to step 130-4, the vector 58 in the direction connecting the tip of the coating gun 56 and the display point 52 on the virtual surface 50 is calculated by the display point projecting means 26. Next, proceeding to step 130-5, the display point 52 on the virtual plane 50 is
It is projected by the display point projection means 26 on the painted surface 54 existing in the vector direction. When the display point 52 on the virtual surface 50 is projected on the surface 54 to be coated, the routine proceeds to step 130-6, where it is judged whether or not the projected distance is within Lmm from the tip of the coating gun 56.

The judgment in step 130-6 is that if the projection distance is set to infinity, all the paint adheres in the simulation although the paint does not reach because the distance to the surface to be painted 54 is actually long. Because it will be done. The standard value of the projection distance L has been previously obtained through experiments. In step 130-6, the projection distance is Lm.
If it is determined that it is not within m, step 130-4
Then, the above process is repeated for another display point.

If it is determined in step 130-6 that the projection distance is within Lmm, step 130
Proceeding to -7, projection display of the display point 52 on the painted surface 54 by the display 20 is performed. FIG. 8 shows the painted surface (vehicle bumper) 5 displayed on the screen of the display 20.
4 shows an example of the film thickness distribution of the paint in No. 4. As shown in FIG. 8, by displaying the film thickness distribution of the surface 54 to be coated by projecting the display points 52 onto the surface 54 to be coated, the film thickness distribution can be easily grasped visually. That is, since the high density portion of the display points 52 projected on the surface 54 to be coated has a large film thickness and the low density portion of the display points 52 has a small film thickness, which portion should be corrected for the coating condition is a glance. Can be grasped at.

If it is determined in step 130-8 that the generation of the points proportional to the film thickness value has ended, the process proceeds to step 140 in FIG. 5 to determine whether or not the robot operation simulation has all ended. To be done. Here, if it is determined that the robot operation simulation is not yet completed, the process returns to step 120, and the film thickness display process in the next one interpolation is continued.

Also in the next one interpolation shown in FIG. 2, the display points are overlapped by generating the number of display points on the virtual surface based on the film thickness value of the table data and projecting them on the surface to be coated, as described above. , You can simulate the situation of painting with the painting robot on the screen. As described above, when all the projection display of the display points 52 on the painted surface 54 based on the robot operation program is completed, the process proceeds to step 150 and the film thickness display simulation process is completed.

As shown in FIG. 8, the film thickness distribution is indicated by a display point 52.
By displaying by projection on the surface 54 to be coated, the film thickness distribution can be easily visually grasped from the scattered state, and the simulation coating conditions can be easily corrected. Further, since the raw data of the film thickness distribution actually obtained by the coating experiment is used, it is possible to display the film thickness distribution close to the actual coating work by the coating robot. Therefore, the actual teaching (creating an operation program) of the actual coating robot based on the teaching data of the coating film thickness distribution computing device 1 becomes easy, and the man-hour required for the precise teaching can be greatly reduced.

FIG. 7 shows the film thickness value calculation process. The process of FIG. 7 calculates the film thickness value of an arbitrary portion on the surface 54 to be coated, based on the point density of the display points 52 projected on the surface 54 to be coated displayed by the film thickness display process of FIG. It is a thing. In step 200 of FIG. 7, by operating the mouse 23, the intersection point (54a) on the painted surface 54 designated by the cursor displayed on the screen of the display 20 is calculated. Next, in step 230, it is determined whether or not the processing has been completed by the number of display points 52 projected on the surface 54 to be coated. Here, display point 5
If it is determined that the processing for the number of 2 has not been completed, the process proceeds to step 210.

In step 210, it is sequentially determined whether or not the projected display point 52 exists within a circle having a radius S centering on the intersection. When it is determined in step 210 that the projected display points 52 are present within the circle having the radius S centering on the intersection, the process proceeds to step 220, and the number of projected display points 52 is accumulated, and step After making a determination at 230 for all projected display points 52,
Go to step 250. In step 250, the cumulative number of the projected display points 52 is displayed on the screen of the display 20 as a film thickness value.

As described above, by moving the cursor on the screen of the display 20 with the mouse 23, it is possible to display the film thickness value of an arbitrary part of the surface 54 to be coated, so that the film thickness distribution can be numerically calculated. It becomes possible to grasp easily. Therefore, it becomes easy to judge how much the correction amount of the film thickness value should be set, and the work amount for creating the operation program of the coating robot can be reduced.

Second Embodiment As shown in FIG. 10, the computer 10 is provided with a holding surface determining means 63 and a film thickness value calculating means 64.
The gripping surface determining means 63 and the film thickness value calculating means 64 are constituted by programs stored in the computer 10. A storage unit 61 and a film thickness distribution storage unit 62 are formed on the hard disk 12. The storage means 61 stores, for example, the shape of the coating robot for simulation (algorithm for determining the posture of the robot), the work to be coated, teaching work data (data such as coating position, coating speed, coating pattern width, etc.). There is. Also, the storage means 6
1, the tip position of the coating gun 70 and the coating direction vector (O: Orient, A: approach) are set (stored) as data for each interpolation point based on the teaching position of the coating gun 70 as shown in FIG. To be done.

In the film thickness distribution storage means 62, the coating film thickness distribution for the coating conditions obtained by the coating experiment is stored as table data. In the film thickness measurement in the coating experiment, the film thickness after baking is measured. The test piece 66 shown in FIG. 12 was used for the coating experiment. In the coating experiment of this example, unlike the one-shot coating of the first example, continuous coating was performed in the direction of the arrow, and the film thickness value at a certain cross section was measured at regular intervals (for example, 10 mm) to obtain a standard film. The thickness distribution data was μ. In this case, table data for many coating conditions can be obtained by conducting experiments with many levels such as the gun distance (distance from the tip of the coating gun to the surface to be coated), gun speed (coating speed), and paint discharge rate. It is possible to expect the improvement of the film thickness value calculation accuracy.

The holding surface determining means 63 is a simulation
An arbitrary value for obtaining the film thickness value on the upper coated surface 71
Point X₀Specify with the cursor (to operate the mouse 23
Specified), interpolation point Q₁, Q₂Application direction vector
Le O, A (O₁, A₁And O₂, A₂) Made by instructions
Part X₀Virtual holding surface (infinite virtual surface) 72, 7
It has the function of determining 3. The film thickness value calculating means 64 includes
Simulate via keyboard 16 as input means
You can enter the painting conditions. Membrane value calculator
64 is the designated site X₀From the relationship between the holding surfaces 72 and 73
Interpolation point Q₁, Q ₂Tip position P of the painting gun 70 between₀Seeking
Therefore, the tip position P of the coating gun 70₀And designated part X₀And stains
Film thickness distribution data for coating conditions
From the relationship with₀Is the coating film thickness from the coating experiment
Understand which part of the distribution corresponds to the indicated part X₀
It has a function of calculating the film thickness value in. Display means
The display 20 as the
It has a function to display the calculated film thickness value.

Next, the operation of the coating film thickness distribution calculating apparatus according to the second embodiment will be described. FIG.
Shows a processing procedure of a robot operation simulation in the coating film thickness distribution computing device 1. The robot operation simulation of FIG. 13 is performed by a program that has been previously taught on a CAD system (robot simulation application). Step 30 of FIG.
At 0, necessary data is read into the work area in the RAM of the computer 10. The necessary data are the shape of the painting robot, the work to be painted, and teaching work data which are already stored in the storage means 61 of the hard disk 12. When the process of step 300 is completed, the process proceeds to step 310, where the keyboard 16 inputs the coating conditions for the simulation to the computer 10.

When the simulation coating conditions are set, the process proceeds to step 320, the coating robot operation simulation on the screen of the display 20 is started, and the coating robot performs the coating work on the screen. The trajectory of the coating robot is generated for each of the above-described interpolations (for example, 0.05 seconds in the present embodiment), and continuous coating simulations can be performed by continuing this. Here, the interpolation points are different from the teaching positions, and normally there are many interpolation points between the teaching positions.

At the interpolation point, as shown in step 330, the tip position of the coating gun 70 and the coating direction vector (O: Orient, A: Approach) are stored. In step 340, it is determined whether or not the robot motion simulation is completed. If it is not completed, the process returns to step 320. If it is completed, step 35 is executed.
The process proceeds to 0, and the robot operation simulation process ends. After the processing of FIG. 13, the film thickness value calculating means 6 of FIG.
When only the calculation of the film thickness value by 4 is executed, that is,
If it is not necessary to confirm the robot operation, it is not necessary to simulate the robot operation on the screen, and only the locus may be generated internally (Dry Ru
n).

FIG. 14 shows the film thickness value calculation processing.
This film thickness value calculation process can be performed by preparing the film thickness distribution data μ by the coating experiment of FIG. 12 and the data by the robot operation simulation process of FIG.
In step 400 of FIG. 14, when the designated portion X ₀ , which is the portion where the film thickness value on the coated surface 71 of FIG. 9 is to be calculated, is designated by the cursor, the position (x) of the intersection point in the vertical direction on the screen of the display 20 (x ₀ , y ₀ , z ₀ ) is obtained. Next, the time when the coating was applied to the designated portion x ₀ , that is, the trajectory of the coating robot (the position of the coating gun) at which the film thickness was formed is searched. To this end, first, the process of step 410 is performed.

In step 410, two planes that sandwich the designated portion X ₀ are calculated. In FIG. 9, it is assumed that the infinite virtual planes 72 and 73 at the interpolation point Q ₁ and the interpolation point Q ₂ are in a positional relationship of sandwiching the designated portion X ₀ . This narrows down to which interpolation point the designated portion X ₀ is painted during operation. Figure 15
Shows a process of calculating the infinite virtual planes 72 and 73 that sandwich the designated portion X ₀ . In step 410-1 of FIG. 15, the tip position of the coating gun 70 of FIG. 9 and the coating direction vector are used to sequentially calculate a surface formed by the two vectors (O, A) for each interpolation point, The infinite virtual plane is used to extract the ones existing in a positional relationship that sandwiches the designated portion X ₀ .

Here, there are cases where the same portion of the surface to be coated 71 is coated in duplicate due to the teaching relationship.
There may be two or more sets of infinite virtual planes that sandwich the designated portion X ₀ . As a method of extracting the infinite virtual surface, in step 410-2, the coordinate value of the designated portion X ₀ designated in the formula of FIG. 16 and the following mathematical formula is substituted, and the resulting value is obtained in step 410-3. We will search for two faces that are "positive → negative" or "negative → positive". Calculated value t
16 shows the direction of the foot of the perpendicular drawn from the coordinate value of the designated portion X ₀ in FIG. 16, and the positive / negative of this indicates that the two infinite virtual planes 72 and 73 are in a positional relationship of sandwiching the designated portion X _0. Means to be in.

[0039]

[Equation 1]

If it is determined in step 410-3 that the value of t is opposite to that of the immediately preceding value, the process proceeds to step 410-4, and in step 410-5, these two surfaces are designated as the designated parts. processing the X ₀ as two surfaces sandwiching, the process proceeds to step 420 following processing. If it is determined in step 410-3 that the value of t is not reversed from that of the immediately preceding value, the process proceeds to step 410-6. here,
From the relationship between W and dd described later, it is determined whether or not the range in which the film thickness is formed is sandwiched between the two infinite virtual surfaces 72 and 73. In step 410-6, W> dd
If it is determined that W> dd, then the process returns to step 410-1. If it is determined that W> dd is not satisfied, step 41
The process proceeds to 0-7, and since there is a possibility that a film thickness may be formed although it is not sandwiched by the infinite virtual surfaces 72 and 73, the process proceeds to step 420 of the next process.

19 and 20 refer to the two infinite virtual surfaces 72 and 73 from above. As shown in FIG. 19, W (distance between intersection of two planes and O ₁ and center of film thickness distribution data μ) and dd (film thickness of film thickness distribution data μ in FIG. 9) When the relation of (maximum pattern from the distribution center) is W> dd, the range in which the film thickness is formed is sandwiched between the two infinite virtual planes 72 and 73, and therefore calculation is possible, but as shown in FIG. In the case of W <dd, a part of the range where the film thickness is formed is two infinite virtual surfaces 72,
There is a phenomenon that the calculation is not performed correctly because it is not sandwiched by 73. That is, as shown in FIG. 20, the film thickness should have been actually formed by the movement of the film thickness distribution data μ, but since the film is not pinched by the two infinite virtual planes 72 and 73 in position, the value of t is positive or negative. Is not changed. Therefore, in this case, it is necessary to calculate the film thickness value by performing the same processing as in the case of being sandwiched between the two infinite virtual surfaces 72 and 73.

When one infinite virtual surface and the next infinite virtual surface are parallel (ψ = 0), the normal vectors of both are in the same direction, and unless there is a designated portion X ₀ between the two infinite virtual surfaces. t
The value of does not reverse the sign from that of the previous one. However,
As a case where a film thickness is formed even if the value of t is not reversed from the positive and negative values, there is a case where one infinite virtual surface and the next infinite virtual surface are rotated by 90 degrees or more. Consider such a case. According to FIGS. 19 and 20, w = v × i
The relationship of / tan (ψ) is established. Here, v: target point velocity in FIG. 9, i: interpolation interval, ψ: angle formed by O ₁ and O ₂ . In this case, if the range of the angle ψ is −π / 2
Considering <ψ <π / 2 (ψ ≠ 0), the angular velocity ω = ψ / i at the target point of the painting robot. Where i = 0.0
Substituting 5 seconds (interpolation interval in a general spray painting robot), ω≈10π is required to rotate ψ to around π / 2. Since it is practically impossible to give an angular velocity of 10π rag / sec to a real robot, the range of ψ is within −π / 2 <ψ <π /
It can be seen that it may be set as 2 (ψ ≠ 0). That is, one infinite virtual surface and the next infinite virtual surface do not rotate more than 90 degrees. For this reason, it may be ignored when rotating 90 degrees or more.

Pointed part X₀Two infinite virtual planes 7
When 2, 73 is calculated, the coating gas is applied in step 420.
The detailed position of the button 70 is determined. Position of tip of coating gun 70
P₀Is the designated site X₀And two infinite virtual planes that sandwich it 7
It is calculated by the positional relationship of 2, 73, and the calculation process is shown in FIG.
Shown in. In step 420-1 of FIG. 17, shown in FIG.
Interpolation point Q₁, Q₂A line 76 parallel to the line 75 connecting the
Rank X₀It is generated so as to pass over, and this parallel line 76 and infinity
Intersection X with virtual planes 72 and 73₁, X₂To step 420
-2. Next, this intersection X₁, X₂And designated site
X₀The ratio (m, n) according to the positional relationship of
-3, and use this ratio to calculate the interpolation point Q ₁, Q₂Among
By dividing the line 75, the tip position P of the coating gun 70
₀Ask for. Tip position P₀Is required, step 4
20-5, and proceeds to the next process (step 430).

At step 430, various values necessary for calculating the film thickness value at the designated portion X ₀ are calculated. FIG.
Shows a processing procedure for calculating various values. In step 430-1 of FIG. 18, the direction vector D and the distance h therebetween are calculated by connecting the tip position P ₀ of the coating gun 70 and the designated portion X ₀ . Further, in step 430-2, approach vector A ₀ interpolation points Q _1, closer to Q ₂ (interpolation point in FIG. 9 Q at the tip position P _0
In step 430-3, the angle θ formed by the approach vector A ₀ and the direction vector D is calculated instead. Further, in step 430-4, the velocity is calculated by the distance between the intersections X ₁ and X ₂ on the infinite virtual surface and the moving time T ₀ between the interpolation points Q ₁ and Q _{2 of the} robot coating gun, and this is aimed at. It is determined as the point velocity V. When the target point velocity V is calculated, the process proceeds to step 430-5 and proceeds to the next process.

When the direction vector D, the distance h, the angle θ, and the target point velocity V are calculated in step 430 of FIG. 14, the process proceeds to step 440. In step 440, FIG.
And the pattern distance d from the film thickness distribution center of the film thickness distribution data μ is calculated from the gun distance g and the angle θ in the coating experiment shown in FIG. The pattern distance d is d = g · tan
It can be calculated by θ. In step 450, as shown in FIG. 11, the film thickness distribution _value μ ₀ at the pattern distance d is referred to from the film thickness distribution data μ stored in the film thickness distribution storage means 62 as table data.

The film thickness distribution data μ to be referred to is a simulation.
It corresponds to the application coating conditions, and the simulation
If there is no film thickness distribution data μ that is exactly the same as the coating conditions
Is the film thickness distribution data closest to the simulation coating conditions.
Is referred to. As shown in FIG. 11, the film thickness value μ₀Is
It is a value corresponding to the pattern distance d in the coating experiment.
And the film thickness value μ₀Is the indicated part X₀Is corrected to the film thickness value at
Be done. This correction consists of two steps, gun distance correction and gun speed.
Step on. In step 460, the film thickness value μ ₀The gun
Distance correction is performed and the corrected film thickness value μ₁Is μ₁= Μ
₀It is calculated by xg / hcos θ.

Film thickness value μ₀When the gun distance correction of
Proceed to step 470, and the film thickness value μ₁Based on gun
Speed correction is performed. Target speed V is the coating during the coating experiment
If it is different from the moving speed of the gun, the designated area X₀In
Film thickness is μ₁The film thickness value μ
₁To correct. Film thickness value μ by gun speed correction₂Is μ ₂
= Μ₁X (r / T₀) / V. Where r is
Interpolation point Q₁, Q₂Indicates the distance between. In addition, in the painting experiment
Gun distance g and paint gun during simulation
Tip position P₀From the surface to be coated 71 are the same
And the movement speed of the painting gun in the painting experiment
If the target point speed V at the time of operation is the same,
Uncorrected film thickness value μ₀Is the designated part X as it is₀And the film thickness of
Become.

When the film thickness value μ ₂ by the gun speed correction is calculated, the routine proceeds to step 480, where it is judged whether or not the surface sandwiching the designated portion X ₀ is checked at all interpolation points.
If the check at all interpolation points has not been completed, the process returns to step 410 and the above processing is repeated. Step 4
If it is determined at 80 that the checking at all interpolation points has been completed, the process proceeds to step 490, and the film thickness value μ ₂ is calculated between all the target interpolation points and accumulated. The process of step 490 is performed when the designated portion X ₀ has two infinite virtual surfaces 7
2,73 not limited to only being sandwiched, when the instruction portion X ₀ by the relationship of the teaching are painted from a different direction, infinite virtual surface sandwiching the instruction portion X ₀ is made larger than this, the results This is because the film thickness value is cumulatively accumulated. The cumulative film thickness value Σμ ₂ calculated in step 490 is displayed as the final film thickness value on the screen of the display 20 in step 500. Therefore, the film thickness value at the designated portion X ₀ can be geometrically calculated and calculated.

In the case of the first embodiment, all coating operations are simulated, display points corresponding to the film thickness values are generated at all interpolation points, and the film thickness value is obtained from the point density of the display points. To change the conditions and obtain the film thickness value,
It takes a lot of time because it is necessary to simulate all painting operations and generate new display points again. In contrast, even in the second embodiment changes the coating conditions, since the coating direction vector after simulated once every painting operations at each interpolation point has already been grasped, the spray gun to the indicated site X _o It is possible to specify 70, and it is not necessary to simulate all painting operations again. Therefore, when it is desired to change the coating condition and obtain the film thickness value, only the film thickness distribution data corresponding to the coating condition input from the keyboard 16 needs to be newly fetched, and the film at an arbitrary designated portion X _o . The thickness value can be obtained in a short time.

[0050]

According to the present invention, the following effects can be obtained. (1) In the coating film thickness distribution computing device according to claim 1, based on the coating conditions for the simulation set,
The display point generation means selects the table data of the film thickness value distribution stored in the film thickness distribution storage means, and the coating film thickness distribution of the selected table data is set to this film thickness on the virtual surface in front of the paint spraying direction. Generated in the form of a number of display points according to
Since the display points generated on the virtual surface are projected onto the surface to be coated by the display point projection means, the film thickness distribution can be easily grasped from the scattered state of the display points on the surface to be coated.
In addition, since the raw data of the film thickness distribution obtained by the coating experiment is used, it is possible to display the film thickness distribution close to that of the coating operation by the actual coating robot. Therefore, in the actual teaching by the coating robot, the teaching data by the coating film thickness distribution computing device can be effectively used, and the number of steps required for the precise teaching (creating the operation program) of the coating robot can be significantly reduced. Further, by reducing the work amount of the precise teaching, it is possible to reduce the amount of paint, thinner or the like used in the precise teaching as compared with the conventional technique, and the dangerous work by handling the coating robot is reduced. (2) In the coating film thickness distribution calculating device according to claim 2, the film thickness value at an arbitrary portion of the coating surface is calculated based on the point density of the display points projected on the coating surface by the display point projecting means. Since the value is calculated by the value calculating means, it is possible to easily numerically grasp the film thickness value at an arbitrary site. Therefore, the correction amount of the film thickness value can be quickly determined, and the working efficiency of the simulation can be improved. (3) In the coating film thickness distribution computing device according to claim 3, a coating direction vector is set for each interpolation point based on the teaching position of the coating gun, and the surface to be coated is a virtual surface created by this coating direction vector. The sandwiching surface for sandwiching an arbitrary designated portion in is determined by the sandwiching surface determining means, and the film thickness value calculating means determines the position of the coating gun between the interpolation points from the relationship between the designated portion and the sandwiching surface, and the coating gun Since the film thickness value at any designated portion on the surface to be coated is calculated based on the position, designated portion, and the coating film thickness distribution of the table data for the coating conditions to be simulated, the coating condition is changed to change the designated portion. Even when obtaining the film thickness value, it is not necessary to simulate all the coating operations, and the work efficiency of the film thickness value correction can be further improved.

[Brief description of drawings]

FIG. 1 is a control block diagram of a coating film thickness distribution computing device according to a first embodiment of the present invention.

FIG. 2 is a schematic diagram showing a simulation state during one-shot coating in the apparatus of FIG.

FIG. 3 is a schematic diagram showing a film thickness distribution on a virtual plane of FIG.

FIG. 4 is a schematic configuration diagram of the apparatus of FIG.

5 is a flowchart showing an overall processing procedure of a film thickness display simulation in the apparatus of FIG.

6 is a flowchart showing a control process in the film thickness display of FIG.

7 is a flowchart showing a control process in a film thickness value calculating means of the apparatus of FIG.

8 is an image showing a film thickness distribution of a vehicle body displayed on the display means of FIG.

FIG. 9 is a conceptual diagram of film thickness value calculation by a coating film thickness distribution calculation device according to a second embodiment of the present invention.

FIG. 10 is a control block diagram of a coating film thickness distribution computing device according to a second embodiment of the present invention.

FIG. 11 is a schematic diagram showing the relationship between the coating gun, designated portion, and film thickness distribution in FIG.

FIG. 12 is a perspective view showing a coating experiment method for obtaining the film thickness distribution data of FIG. 11.

13 is a flowchart showing a procedure of robot operation simulation processing by the apparatus of FIG.

14 is a flowchart showing a procedure of film thickness calculation processing by the apparatus of FIG.

FIG. 15 is a flowchart showing a control process in step 410 of FIG.

16 is a schematic diagram for explaining a procedure for obtaining an infinite virtual plane that sandwiches a designated portion in the control process of FIG.

17 is a flowchart showing a control process in step 420 of FIG.

FIG. 18 is a flowchart showing a control process in step 430 of FIG.

FIG. 19 is a schematic diagram showing a state in which the range in which the film thickness is formed in FIG. 9 is entirely sandwiched by two infinite virtual surfaces.

20 is a schematic diagram showing a state in which a part of the range where the film thickness is formed in FIG. 9 is not sandwiched by two infinite virtual surfaces.

[Explanation of symbols]

1 Coating Thickness Distribution Calculation Display Device 10 Computer 13 Storage Means 14 Film Thickness Distribution Storage Means 24 Display Point Generating Means 26 Point Projecting Means 28 Film Thickness Value Calculating Means 50 Virtual Surfaces 52 Display Points 54 Painted Surfaces 61 Storage Means 62 Film Thicknesses distribution storage unit 63 sandwiching surface determining means 64 thickness value calculating means 70 spray gun 71 to be coated surface 72 clamping surface 73 clamping surface μ thickness distribution data Q ₁ interpolation point Q ₂ interpolation point X ₀ instruction site

Claims (3)

[Claims] 1. A storage means for storing a shape of a coating robot, a work to be coated, and teaching work data, and a film thickness distribution for storing the coating film thickness distribution for a number of coating conditions obtained by a coating experiment as table data. When the storage means and the coating conditions to be simulated are set, table data to be referred to corresponding to the set coating conditions is selected from the table data, and the coating film thickness of the selected table data is displayed on the virtual surface in front of the paint spraying direction. Display point generating means for generating a distribution in the form of display points of a number corresponding to the film thickness; and display point projecting means for projecting the display points on the virtual surface onto the coated surface of the work. Characteristic paint film thickness distribution calculator. 2. A film thickness value calculating means for calculating a film thickness value at an arbitrary portion of the surface to be coated based on the point density of the display points projected on the surface to be coated by the display point projecting means. The coating film thickness distribution calculation device described. 3. A film thickness distribution storage means for converting the coating film thickness distribution for the coating conditions obtained by a coating experiment into table data and storing it, and a memory for setting a coating direction vector for each interpolation point based on the teaching position of the coating gun. Means, a sandwiching surface determining means for determining a sandwiching surface that sandwiches an arbitrary designated portion of the surface to be painted among virtual surfaces created by the coating direction vector of the interpolation point, and a relationship between the designated portion and the sandwiched surface. The position of the coating gun between the interpolation points is obtained from the position of the coating gun, and based on the coating thickness distribution of the table data for the coating gun position and the designated portion and the coating conditions to be simulated, the film thickness value at any designated portion of the surface to be coated is calculated. A coating film thickness distribution calculating device, comprising: a film thickness value calculating means for calculating.