JPH10296150A - Jetting abnormality decision system of building plate coating device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To automatically and accurately detect jetting abnormality of jetting nozzles. SOLUTION: A paint receiving unit 35 provided with plural paint receiving parts 35 in the arrangement direction of jetting nozzles 19 of an ink jet type coating device 12 is arranged below the jetting nozzles 19 and the paint jetted from the jetting nozzles 19 every coating of the prescribed number of building plates 11 is received and stored by each of the paint receiving parts 35. Then, a paint storage state in each of the paint receiving parts 35 is picked up by a digital camera 42. The jetted quantity Qi per unit time of the paint jetted into each of the paint receiving parts 35 is calculated by using an image processing technique and by deciding whether or not the calculated jetted quantity Qi is within the range of a jetted quantity control width P making the reference jetted quantity Qs as the central value, whether or not there is the jetting abnormality in jet nozzles 19 is decided. Furthermore, by turning each of the paint receiving parts 35 downward by a pulse motor 36, the measured paint is discharged and received by a paint recovery tray 14 to recover it.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an injection abnormality judging system for a building board coating apparatus for judging abnormal injection of a building board coating apparatus which sprays paint from an injection nozzle.

[0002]

2. Description of the Related Art In recent years, ceramic building boards, whose demand has been rapidly increasing, often have a design that is enhanced by painting a pattern on the surface. In the case of painting a pattern on an uneven surface of a building board, as shown in JP-A-7-228036, a painting technique for drawing a pattern on the surface of the building board in a non-contact manner using an ink jet type coating apparatus has been developed. Have been. In this ink jet type coating apparatus, a large number of spray nozzles for spraying paint are arranged in a direction perpendicular to the direction of transport of the building board, and while the building board is being transported by a conveyor, the electromagnetic valves of each spray nozzle are turned on / off by a computer. By controlling (paint spray / stop), the pattern is painted on the surface of the building board.

[0003]

In this ink jet type coating apparatus, the coating on the surface of the building board has an "insufficient amount of coating" or " Coating defects such as “uneven coating” may occur. Once a defective paint plate occurs due to such an abnormal injection, no abnormal spray of the injection nozzle is found until a defective paint plate is detected in the inspection process on the downstream side of the paint line, and a large number of defective paint plates are produced. .

[0004] As a countermeasure, there is a case where a test coating is performed before the start of operation of the coating line, and an inspection for visually confirming whether or not the injection nozzle has no injection abnormality and the coating state is good is performed, and then the actual coating is performed. However, there is a drawback that the judgment by visual inspection has individual differences and the accuracy is not very good. In addition, visual inspection requires human labor, takes time, and reduces productivity.

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and accordingly, has as its object the purpose of a spraying apparatus for a building board coating apparatus capable of automatically and accurately detecting a spraying abnormality which causes a coating failure. An object of the present invention is to provide an abnormality determination system.

[0006]

In order to achieve the above object, according to the present invention, there is provided a system for judging a jetting abnormality of a building board coating apparatus, comprising the steps of: In the apparatus for judging the presence / absence of abnormal injection of a building board coating apparatus that sprays and paints paint from a plurality of spray nozzles arranged in a plurality of spray nozzles, the spray amount of paint sprayed from the spray nozzle is determined for each of the spray nozzles or The apparatus is provided with an injection amount measuring means for measuring a plurality of injections, and an injection abnormality determining means for determining the presence or absence of an injection abnormality based on the measurement result of the injection amount measuring means.

[0007] According to this configuration, the amount of paint sprayed from the spray nozzle is measured, and the presence or absence of a spray abnormality is determined based on the measurement result of the spray amount. Can be automatically detected. Moreover, since the amount of paint sprayed is measured for each spray nozzle or for each spray nozzle, it is possible to grasp the spray status for each spray nozzle or for each spray nozzle.

[0008] In this case, as in claim 2, the injection amount measuring means stores a plurality of paints sprayed from the injection nozzles at the time of the measurement of the injection amount separately for each of the injection nozzles or for each of the plurality of injection nozzles. A configuration including a paint receiving portion and a storage amount measuring means for measuring a paint storage amount in each paint receiving portion,
The injection amount of the injection nozzle may be measured from the paint storage amount in each paint receiving section. As described above, the paint sprayed from the spray nozzle is received by the paint receiving unit, so that the spray amount of the sprayed paint is replaced with the paint storage amount in the paint receiving unit, and the paint storage amount is measured by the storage amount measuring unit. By doing so, the injection amount can be accurately measured.

Further, as in claim 3, the storage amount measuring means includes an image pickup device for picking up an image of a paint storage state in each of the paint receiving portions, and an image signal output from the image pickup device for processing each of the image pickup devices. An image processing means for measuring the amount of stored paint in the paint receiving section may be used. In this configuration, the state of the paint storage in each paint receiving unit is imaged by the imaging device,
The injection amount can be accurately measured in a short time by using the image processing technology.

[0010] According to a fourth aspect of the present invention, each of the paint receiving sections is disposed below the transport path, and a rotation driving means for rotating and driving each of the paint receiving sections; A rotation control unit that discharges the paint in each of the paint receiving units by operating the rotation driving unit to rotate the paint receiving units downward after measuring the paint storage amount may be provided. . In this case, since each paint receiving section is arranged below the transport path, each paint receiving section can be placed on the building board without moving the position of each paint receiving section when the building board passes below the injection nozzle. Does not interfere with transport or spraying paint on building board surfaces. In addition, after measuring the amount of paint stored in each paint receiver, the rotation control means operates the rotation driving means to rotate each paint receiver downward, thereby automatically removing the paint in each paint receiver. Since the discharge is performed, the operator does not need to discharge the paint in each paint receiving portion.

On the other hand, the measurement of the injection amount of the injection nozzle is performed before the operation of the coating line is started, or when the type of the building board to be coated or the coating material or the coating condition is changed.
It may be performed at a timing that does not hinder the operation of the painting line. However, as in claim 5, every time a predetermined number of building boards are painted, the injection amount is measured before the next building board reaches the painting position. The injection amount of the injection nozzle may be measured by the means, and the presence or absence of the injection abnormality of the injection nozzle may be determined by the injection abnormality determination means for each measurement.

As described above, every time a predetermined number of building boards are painted, it is determined whether or not the injection nozzles are abnormal during the operation of the coating line. If an injection abnormality of the injection nozzle occurs during operation of the coating line, it can be detected immediately. In addition, since the injection amount of the injection nozzle is measured before the next building board reaches the painting position after the predetermined number of building boards have been painted, it hinders painting of building boards and slows down the transport speed of the painting line. It does not become.

Further, the coating of the building board may be stopped by the coating stop means when the injection abnormality determination means detects the injection abnormality of any of the injection nozzles. With this configuration, the coating of the building board can be automatically stopped when the injection abnormality determination unit detects the injection abnormality of the injection nozzle, so that the number of defective paint plates caused by the injection abnormality can be minimized.

Further, the alarm means may be activated when the injection abnormality determining means detects an injection abnormality of any of the injection nozzles. With this configuration, even if the worker is away from the painting line, the worker can immediately know that the injection abnormality has occurred from the warning operation of the warning means.

Further, when the injection abnormality determining means detects an injection abnormality of any of the injection nozzles, information on the injection abnormality may be output by the abnormality information output means. According to this configuration, the specific situation of the injection abnormality of the injection nozzle can be grasped in detail from the output information of the abnormality information output unit.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIG.
This will be described with reference to FIGS. First, a configuration of an ink jet type coating apparatus 12 used for coating a ceramic building board 11 will be described with reference to FIG. The transport path 13 for transporting the building board 11 is configured by transport rollers 14. A coating unit 15 is provided above the transport path 13, and the coating head 1 is provided in the coating unit 15.
6, an electromagnetic valve array 17 and a nozzle array 18 are provided. On the lower surface of the nozzle array 18, a large number of ejection nozzles 19 are provided in a downward direction.
9 are arranged in a row in a direction perpendicular to the direction of transport of the building boards 11, for example, with a nozzle width of 55 cm. Solenoid valve array 17
Are provided with the same number of solenoid valves 20 as the number of the injection nozzles 19, the inlet of each solenoid valve 20 is connected to the coating head 16 via a pipe 21, and the outlet of each solenoid valve 20 is connected via a pipe 22. Connected to each injection nozzle 19.

The inlet of the coating head 16 is connected to a closed paint tank 23 through a paint supply pipe 24, and supplies low-pressure compressed air from the compressor 25 into the paint tank 23 via a pressure regulating valve 26. Thus, while keeping the pressure in the paint tank 23 constant, the paint in the paint tank 23 is pressure-fed to the coating head 16 through the paint supply pipe 24, and the paint in the coating head 16 is piped 21 → the solenoid valve 20 → pipe. The paint is distributed from the injection nozzle 19 when the solenoid valve 20 is opened by distributing the paint on the path from 22 to the injection nozzle 19.

The paint head 16 is provided with a paint return pipe 28 for returning excess paint to the paint collection tank 27 on the side opposite to the paint supply pipe 24.
The paint flowing into the paint head 16 from the paint head 1
6 flows toward the paint return pipe 28 side. A flow control valve 29 for adjusting the flow rate of the paint in the coating head 16 is provided in the paint return pipe 28.
, And the pump 3
0 returns the paint tank 23.

Next, the configuration of an injection amount measuring device 31 (corresponding to an injection amount measuring means) for measuring the injection amount of the paint injected from the injection nozzle 19 will be described with reference to FIGS.
A paint receiving unit 32 for storing the paint ejected from the injection nozzle 19 at the time of measuring the injection amount is located directly below the injection nozzle 19 and below the transport path 13, and via a rotating shaft 33 attached to both sides. And is rotatably supported by the support frame 34. As shown in FIG. 3, the paint receiving unit 32 is formed of a rectangular parallelepiped container extending in the arrangement direction of the injection nozzles 19 and having an open upper surface, and the front surface thereof is formed of a transparent acrylic resin plate 32a. The inside of the paint receiving unit 32 is equally partitioned by, for example, 19 transparent acrylic resin thin plates 32 b, so that, for example, 20 paint receiving portions 35 having the same volume are formed in the arrangement direction of the injection nozzles 19. The rear surface of the paint receiving unit 32 is painted black, and each paint receiving portion 3
When the paint is stored in 5, the liquid level of the paint can be clearly seen from the front side.

As shown in FIG. 1, the paint receiving unit 32
Below the rear side, a pulse motor 36 is provided as a rotation driving means for rotationally driving the paint receiving unit 32, and a sprocket 38 fitted on a rotation shaft 37 of the pulse motor 36, an intermediate sprocket 61, The sprocket 39 fitted on the rotating shaft 33 of the paint receiving unit 32 is connected via chains 40a and 40b.
Thus, when the pulse motor 36 rotates, the rotational motion is transmitted to the paint receiving unit 32 via the chains 40a and 40b, so that the paint receiving unit 32 rotates according to the rotation direction and the rotation angle of the pulse motor 36, Each paint receiving portion 35 faces downward or upward. Note that a potentiometer 41 (see FIG. 4) for detecting the rotation angle of the rotation shaft 33, that is, the rotation angle of each paint receiving portion 35, is attached to the rotation shaft 33 of the paint receiving unit 32.

A digital camera 42 as an image pickup device and an illumination lamp 4 are provided in front of the paint receiving unit 32.
3 is installed so as to face the paint receiving portion 35, and the front surface of the paint receiving unit 32 (a transparent acrylic resin plate 32a)
The digital camera 41 captures an image of the paint storage state in each paint receiving section 35 through the. Further, below the paint receiving unit 32, a paint collecting tray 44 for receiving and collecting paint discharged from each paint receiving portion 35 is provided. A photoelectric switch 45 for counting the number of painted building boards 11 is provided below the painting unit 15.
The light projecting element and the light receiving element of the photoelectric switch 46 for detecting that the upper part of the paint receiving unit 32 protrudes into the conveying path 13 are disposed on the conveying path 13. It is installed so as to sandwich the upper part of the paint receiving unit 32 immediately below the upper part 13.

Next, the configuration of the control system of the coating line will be described with reference to FIG. The operation of the coating line is performed by the first controller 4 composed of electronic components mainly composed of a computer.
7, controlled by the second controller 48 and the third controller 49. The first controller 47 is a main controller that manages the operation of the entire coating line, reads signals output from the photoelectric switch 45 and the third controller 49, and reads the signals output from the solenoid valve 20, the flow rate adjustment valve 29,
Outputting signals to the second and third controllers 48 and 49;
Ink-jet type coating device 12 and injection amount measuring device 3
1 is controlled.

On the other hand, the second controller 48 controls the pulse motor 36 for driving the paint receiving unit 32 to rotate. The first controller 47 and the potentiometer 4
1 and a signal output from the photoelectric switch 46, and outputs a signal to the pulse motor 36 to control the rotation driving of the paint receiving unit 32. This second controller 4
8 plays a role as a rotation control means referred to in the claims.

The third controller 49 controls the injection amount measurement and the injection abnormality determination. The third controller 49 reads signals output from the first controller 47, the digital camera 42 and the reset button 50, and reads the signals output from the first controller 4
9. Signals are output to the digital camera 42, the illumination lamp 43, the monitor display 51, the printer 52, the alarm buzzer 53 and the alarm lamp 54 as alarm means, and control the injection amount measurement and the injection abnormality determination.

Hereinafter, first to third controllers 47 to 49 will be described.
Will be described. First, the first controller 4
7 will be described with reference to the flowcharts shown in FIGS.

When the main routine of FIG. 5 is started, it is first determined in step 101 whether or not the system power has been turned on. If the system power has not been turned on, the process waits in step 101 until the power is turned on. Thereafter, when the system power is turned on, the process proceeds to step 102, and after performing the initial setting, in step 103, the pattern coating control is performed, and the electromagnetic valves 20 of the respective injection nozzles 19 are turned on / off (paint injection / stop). Is controlled by a preset operation pattern to paint a pattern on the surface of the building board 11.

Then, in the next step 104, after executing the test injection control by the routine of FIG. 6 described later,
Proceeding to step 105, it is determined whether or not all coatings have been completed.
And the test injection control of step 104 are repeatedly executed. Thereafter, when the coating is completed, the process proceeds to step 106, in which the pattern coating control is stopped. In the next step 107, the test injection control is stopped, and then, the process proceeds to step 108, where the second controller 48 is stopped.
Then, a control stop signal is output to the third controller 49, and the main routine ends.

On the other hand, the test injection control in step 104 is executed as follows in accordance with the test injection control routine shown in FIG. First, in step 109, the building board 1
Each time the photoelectric switch 45 detects the passage of 1, the counter counts, and it is determined whether or not the passage of the predetermined number of building boards 11 has been counted, and the passage of the predetermined number of building boards 11 must be counted. If it is, it waits in step 109 until it is counted. Then, a predetermined number of building boards 1
When the passage of 1 has been counted, the process proceeds to step 110,
After the timer 55 is started, in step 111, the flow control valve 29 is throttled to increase the back pressure (injection pressure) in the coating head 16. In the next step 112, the timer 55
Is started, it is determined whether or not a predetermined time t1 has elapsed. If the predetermined time t1 has not elapsed, the routine waits at step 112 until the predetermined time t1 has elapsed. Here, the predetermined time t1 is a time required for increasing the injection pressure to the target pressure.

Thereafter, when a predetermined time t1 has elapsed,
Proceeding to step 113, the solenoid valves 20 of all the injection nozzles 19
Is turned on (opened), the paint is sprayed for test, and the paint is collected in each paint receiving portion 35. And step 11
At 4, the test injection time t2 after the solenoid valve 20 is turned on.
(For example, 30 s) has elapsed, and the time t2
If has not elapsed, the routine waits at step 114 until the time t2 has elapsed. Thereafter, when the time t2 has elapsed, the routine proceeds to step 115, where the solenoid valves 20 of all the injection nozzles 19 are turned off (closed) to stop the test injection of the paint. In other words, the test injection time t2 is different from the paint receiving portion 35.
It is time to spray the paint inside.

During the test injection, step 111
Since the injection pressure of the injection nozzles 19 is adjusted to be higher than usual, it is possible to perform a test injection that also serves to wash each of the injection nozzles 19 and to quickly store the paint in each of the paint receiving portions 35. As a result, the test injection time t2 can be shortened. However, it goes without saying that the test injection may be performed with the injection pressure kept normal without narrowing the flow control valve 29.

Then, in the next step 116, the digital controller 42 instructs the third controller 49 to capture an image of the paint, and the digital camera 42 captures an image of the paint storage state in each paint receiver 35. Thereafter, in step 117, the second controller 48 is instructed to start operation control of the pulse motor 36,
The paint in each paint receiving portion 35 is discharged to the paint collecting tray 44 by rotating each paint receiving portion 35 downward. Thereafter, in step 118, it is determined whether or not there is an instruction to stop painting from the third controller 49. This painting stop instruction is output when an abnormal injection is detected. If there is no instruction to stop painting, the process proceeds to step 119, where the timer 5
5 and the test injection control routine is repeated. If there is an instruction to stop painting from the third controller 49, the process proceeds to step 120, where the pattern painting control is stopped to stop painting of the building board 11, and the test injection control routine ends. This step 120
The process serves as a coating stopping means in the claims.

Here, in steps 113 to 115, when the test injection is performed only during the time t2, each paint receiving portion 35
7 (a) to 7 (f) show an example of the state of the paint stored in the inside (in the figure, the numbers below No. 1 to 20 are attached below the paint receiving portions 35 for explanation). ). No.
A total of 16 spray nozzles 19 are provided for 3 to 18 paint receiving sections.
Is located directly below. No. of both ends. 1, 2 and No.
Regarding the paint receiving portions of Nos. 19 and 20, only the diffusion paint sprayed from the outermost spray nozzle 19 is stored or the spray paint scatters to the side due to the influence of wind or the like. Compared with the 3 to 18 paint receiving sections, the amount of paint storage is reduced. When the injection abnormality is determined, 1,2
And No. The amount of paint stored in the paint receiving portions 19 and 20 is not taken into consideration. Therefore, No. 1, 2, and N
o. The paint receiving portions 19 and 20 may be omitted, and the number of the spray nozzles 19 and the number of the paint receiving portions 35 may be set to the same number, and the spray nozzles 19 and the paint receiving portions 35 may be in one-to-one correspondence.

FIG. 7 (a) shows that the paint is stored in each paint receiving portion 35 on average, and that the paint spraying state is good. (B) shows a variation in the ejection state of each ejection nozzle 19; Nozzle clogging occurs in the injection nozzle 19 near the paint receiving portion of No. 8,
(D) is No. It is considered that there is an abnormality in the injection nozzles 19 near the paint receiving portions 6 to 9. In (e), the injection amount is insufficient as a whole, and it is considered that the injection pressure is reduced. In (f), since the amount of storage on both sides is small, scattering of the spray paint by wind is considered.

As described above, the paint sprayed from the spray nozzles 19 is received by the paint receivers 35 arranged in the arrangement direction of the spray nozzles 19, so that the spray amount of the sprayed paint is stored in each paint receiver 35. It can be replaced with the paint storage amount, and the ejection state of the ejection nozzle 19 can be grasped.

As described above, in the present embodiment, the number (20) of the paint receiving portions 35 is provided larger than the number (16) of the injection nozzles 19 in consideration of the influence of wind and the like. And the number of spray nozzles 19 and the paint receiving portion 35
May correspond to one to one. In this way, the injection status of each injection nozzle 19 can be grasped, and the injection abnormality occurrence nozzle can be specified accurately. Further, the number of the paint receiving portions 35 is set to one of the number of the injection nozzles 19.
/ N (N is an integer) so that one paint receiving section 35 can store the paint sprayed by the plurality of spray nozzles 19, whereby the nozzle group in which the spray abnormality has occurred can be specified.

The control contents of the third controller 49 for judging the presence / absence of the injection abnormality of the injection nozzle 19 based on the amount of the paint stored in each paint receiving portion 35 are shown in FIGS.
11 and FIG. 11 to FIG. First, in step 201 of FIG. 8, it is determined whether or not the system power is turned on. If the system power is not turned on, the process waits in step 201 until the system power is turned on. Thereafter, when the system power is turned on, the process proceeds to step 202 to perform initial setting, and then to the next step 203
Then, it is determined whether or not there is an instruction for imaging the digital camera 42 from the first controller 47, and if there is no instruction, the process waits in step 203 until the instruction for imaging the digital camera 42 is issued from the first controller 47.

Thereafter, when the first controller 47 instructs the digital camera 42 to capture an image, step 20 is executed.
In step 4, the illumination lamp 43 is turned on to illuminate the inside of each paint receiving section 35 through the transparent acrylic resin plate 32a. In the subsequent step 205, the timer 57 is started. Then, in the next step 206, it is determined whether or not the time t3 has elapsed since the start of the timer 57. If the time t3 has not elapsed, the step 2 is continued until the time t3 has elapsed.
Wait at 06. Here, the time t3 is a time required for the digital camera 42 to stand by.

When the time t3 has elapsed after the lighting of the illumination lamp 43, the process proceeds to step 207, where the digital camera 42
The shutter is operated to capture an image of the paint storage state in each paint receiving unit 35, and the timer 57 is reset in the subsequent step 208. At this time, in step 204, the illumination lamp 4
3 is illuminated to illuminate each of the paint receiving portions 35, so that the paint storage state in the paint receiving portion 35 can be maintained even when the factory is dark or when the paint adheres to the transparent acrylic resin plate 32a and becomes dirty. Can be clearly imaged.

On the other hand, in an image obtained by capturing the paint storage state in each paint receiving portion 35 by the digital camera 42, as shown in FIG. 11, the width direction of the paint receiving portion 35 (the arrangement direction of the spray nozzles 19) is obtained by image processing. And the Y axis is set so that the bottom surface of the paint receiving portion is set to Y = 0 in the height direction of the paint receiving portion 35, and the center X in the width direction of each paint receiving portion 35 is set.
The Y coordinate (Yi) of each coating liquid level at the coordinates (Xi) is obtained (i is an integer). From the conversion coefficient c for converting Yi into an actual length and the width dimension a and the depth dimension b in the paint receiving portion 35, the amount of paint stored in each paint receiving portion 35 can be obtained. The time required to store the paint in each paint receiving portion 35 is t2. Accordingly, the spray amount Qi of the paint sprayed into each paint receiving portion 35 per unit time.
Can be calculated by the following equation. Qi = a * b * c * Yi / t2

In step 209 of FIG. 8, the digital camera 42 reads an image signal of the image of the paint storage state, and stores the image signal and the image capturing date and time in the memory 58 of the third controller 49. After this, step 210
Then, based on the read image signal, Yi of each paint receiving section 35 is obtained by the image processing as described above, and the injection amount Qi per unit time is calculated by Qi = a * b * c * Yi / t2. These steps 209 and 210 function as image processing means. Steps 209 and 210 serving as image processing means and the digital camera 42 serving as an image pickup device constitute a storage amount measuring means referred to in the claims.

Thereafter, step 211 of FIG. 9 is executed.
216 function as injection abnormality determination means, and determine whether or not the calculated injection amount Qi is within the range of the injection amount management width P centered on the reference injection amount Qs (see FIG. 12). It is determined whether or not the injection nozzle 19 is abnormal. Specifically, first, in step 211, the difference ΔQi between the calculated injection amount Qi and the reference injection amount Qs is calculated, and the next step 2
At 12, it is determined whether or not | ΔQi | ≦ P / 2, that is, whether or not it is within the range of the injection amount management width P.

When | ΔQi | ≦ P / 2, Qi is within the injection quantity control range, and the routine proceeds to step 213, where it is determined that there is no abnormal injection in the injection nozzle 19, and a mark 1 is added to Qi. . On the other hand, when | ΔQi |> P / 2, that is, when it is out of the injection amount management range, the routine proceeds to step 214, where it is determined whether or not Qi> Qs + P / 2, and Qi> Qs + P / If it is 2, step 21
Proceeding to 5, Qi is larger than the upper limit of the injection amount management range,
It is determined that the injection nozzle 19 has abnormal injection, and the mark 2 is added to Qi. On the other hand, if Qi≤Qs + P / 2, the routine proceeds to step 216, where it is determined that Qi is smaller than the lower limit of the injection amount management range, that the injection nozzle 19 has abnormal injection, and the mark 3 is marked on Qi. .

If it is determined that the injection nozzle 19 has an injection abnormality and the mark 2 or mark 3 is added to Qi in step 215 or 216, the process proceeds to step 217, where the first controller 47 instructs the first controller 47 to stop painting. In the next step 218, the alarm buzzer 53 and the alarm lamp 54 are alarmed, that is, the alarm buzzer 53 is sounded, and the alarm lamp 54 is blinked to indicate that the alarm is being performed.
The operator is informed that the injection abnormality has occurred in 9.

Thereafter, the flow advances to the next step 219, where the marked Qi is stored in the memory 58 of the third controller 49. If it is determined that there is no abnormal injection in the injection nozzle 19 and the mark 1 is added to Qi in step 213, the process directly proceeds to step 219 and the Q
i is stored in the memory 58. Thereafter, step 220
Then, it is determined whether or not a warning is being issued. If not, the process returns to step 203.

On the other hand, when an alarm is being issued in step 220, the flow advances to step 221 in FIG. 10 to output information on abnormal ejection to the monitor display 51 and the printer 52.
Thereby, the screen of the monitor display 51 is shown in FIG.
As shown in FIG. 3, nothing is displayed below the Qi with the mark 1 and a mark 3 is attached below the Qi with the mark 2 to indicate that it is larger than the upper limit of the injection amount management range. At the bottom of Qi, ▽ indicating that the value is smaller than the lower limit of the injection amount management range are arranged side by side in the horizontal direction, and at the same time, the value of each Qi is graphed and displayed below these. Further, the contents of the monitor display are printed out from the printer 52. The process of step 221 functions as an abnormality information output unit together with the monitor display 51 and the printer 52. By outputting the abnormality information, the specific situation of the injection abnormality of the injection nozzle 19 can be grasped in detail.

Then, in the next step 222, it is determined whether or not the printout is completed. If the printout is not completed, the process waits in step 222 until the printout is completed. Thereafter, when the printout is completed, the process proceeds to step 223, where the timer 57 is started again.
In the following step 224, it is determined whether or not a predetermined time t4 has elapsed since the timer 57 was started. here,
The predetermined time t4 is a preset warning operation execution time. If this time t4 has not elapsed, step 22
Proceed to 5 to determine whether the reset button 50 has been turned on. If the reset button 50 has not been turned on,
Returning to step 224, the alarm operation is continued. If the reset button 50 is turned on during the alarm operation, the process proceeds to step 227, where the alarm buzzer 53 is turned off, the alarm lamp 54 is turned off, and the process returns to step 202.

On the other hand, when the time t4 has elapsed at step 224, the routine proceeds to step 226, where the alarm buzzer 5
3 is turned off, the alarm lamp 54 is turned off, the alarm operation ends, and the control routine of the third controller 49 ends.

Next, the control contents of the second controller 48 for controlling the operation of discharging the paint whose storage amount has been measured from each paint receiving portion 35 will be described with reference to the flowchart shown in FIG. First, in step 301, it is determined whether or not the system power is turned on. If the system power is not turned on, the process waits in step 301 until the system power is turned on. Thereafter, when the system power is turned on, the process proceeds to step 302 to perform initial setting, and then to the next step 30
At 3, it is determined from the signal output from the potentiometer 41 whether or not the paint receiving unit 32 is in the upward state shown by the solid line in FIG.
Proceed to 08.

On the other hand, if the paint receiving unit 32 is in the upward state, the process proceeds to step 304, where it is determined whether or not there is an instruction from the first controller 47 to start the operation control of the pulse motor 36. First controller 4
Step 7 waits until there is an instruction to start the operation control of the pulse motor 36 from Step 7.

Thereafter, when there is an instruction from the first controller 47 to start the operation control of the pulse motor 36, the process proceeds to step 305, where the timer 56 is started, and in step 306, the signal output from the potentiometer 41 is output. By rotating the pulse motor 36 on the basis of this, the paint receiving unit 32 is rotated until the paint receiving unit 32 is in a discharge state (downward) shown by a two-dot chain line in FIG. . Then, in the next step 307, it is determined whether or not a time t5 sufficient to discharge all of the paint in each paint receiving unit 35 has elapsed. If the time t5 has not elapsed, the time t5 elapses. The process waits at step 307.

Thereafter, when the time t5 has elapsed, the routine proceeds to step 308, where the pulse motor 36 is rotated based on the signal output from the potentiometer 41 to rotate the paint receiving unit 32 so as to be in the upward state. In the following step 309, it is determined whether or not the paint receiving unit 32 has returned to the upward state based on the signal output from the potentiometer 41. If not, the process returns to step 308, and the pulse returns to the upward state. The motor 36 is rotated. At this time, the photoelectric switch 46
It is also confirmed that the upper end of the paint receiving unit 32 does not protrude onto the transport path 13 of the building board 11 on the basis of the output signal.

When the paint receiving unit 32 returns to the upward state, the routine proceeds to step 310, where the pulse motor 3
6, the rotation of the timer 56 is stopped.
Reset. Thereafter, in step 312, it is determined whether or not there is a control stop instruction from the first controller 47. If there is no instruction, the process returns to step 304. If there is a control stop instruction from the first controller 47, the second controller The control routine of 48 is ended. This eliminates the need for the operator to discharge the paint in each paint receiving unit 35 every time the paint injection amount is measured, and also allows the paint received in the paint collection tray 44 to be reused.

In the above-described control routine of the second controller 48, the paint receiving unit 32 is controlled to be in the paint discharging state (downward) only when the paint is discharged.
In addition, normally, the paint receiving unit 32 may be in the paint discharging state (downward), and the operation may be controlled so that the paint receiving unit 32 is in the upward state only at the time of measuring the paint injection amount. In this way, paint scattered at the time of painting the building board 11 can be prevented from entering the paint receiving portion 35.
An accurate injection amount can be measured, and the accuracy of injection abnormality determination can be improved.

According to the injection abnormality judging system of the embodiment described above, the paint sprayed from the spray nozzle 19 is received by each paint receiving section 35, and the state of the amount of stored paint in each paint receiving section 35 is determined by the digital camera 42. By using the image processing technique, the amount of injection Qi per unit time to be injected into each paint receiving unit 35 is calculated, and based on the result, it is determined whether or not the injection is abnormal. This eliminates the need for a manual inspection that requires manual labor and is inefficient and inaccurate, and automatically and accurately detects an abnormal injection of the injection nozzle 19 that causes a defective painting of the building board 11. Can be.

In the present embodiment, the digital camera 42 captures an image of the stored state of the paint stored in each paint receiving section 35.
It is needless to say that the state of the paint storage in the paint receiving unit 35 may be imaged using another imaging device such as a video camera, not limited to 2.

In addition to using the imaging device, for example,
A liquid level sensor such as an ultrasonic sensor is installed above each paint receiving portion 35, and the height Hi (corresponding to cYi in the embodiment) of the liquid level of the paint received and stored in each paint receiving portion 35 is measured. ,
The storage amount is obtained from this measurement value, and the injection amount per unit time Q
i may be calculated.

Further, in the present embodiment, each paint receiving portion 35
Calculates the injection amount Qi per unit time of the paint injected into the inside, and determines whether the calculated injection amount Qi is within the range of the injection amount management width P centered on the reference injection amount Qs (see FIG. 12). By determining whether or not there is an abnormality in the ejection of the ejection nozzle 19, the liquid level of the paint in each paint receiving unit 35 measured using an imaging device, a liquid level sensor, or the like is determined. By determining whether the height Hi is within the range of the liquid level height management width R centered on the reference liquid level height Hs, it is determined whether or not the injection nozzle 19 has abnormal injection. Is also good.

On the other hand, in the present embodiment, the injection amount of the injection nozzle 19 is measured each time the passage of a predetermined number of building boards 11 is counted, and it is determined whether or not the injection is abnormal. It is possible to periodically check the presence or absence of abnormal spraying of the spray nozzle 19 during the operation of the coating line.
If an abnormal injection occurs, it can be detected immediately. In addition, when it is determined that there is an abnormal injection, the coating of the building board 11 is automatically stopped, so that the defective coating caused by the abnormal injection is detected in the inspection process downstream of the coating line as in the related art. Until then, no abnormal injection of the injection nozzle is found, and a large number of defective paint plates are not produced in large quantities, the number of defective paint plates caused by abnormal injection can be minimized, and the yield of the building board 11 can be reduced. It will be improved.

However, the injection amount of the injection nozzle 19 is measured each time the passage of a predetermined number of building boards 11 is counted, and it is not determined whether or not the injection is abnormal. The injection amount of the injection nozzle 19 may be measured at a timing that does not hinder the operation of the coating line, such as when changing the type of the building board 11 or the type of the coating or the coating condition, and it may be determined whether or not the injection is abnormal. Even in this case, the intended object of the present invention can be sufficiently achieved.

Further, in the present embodiment, the paint sprayed from the spray nozzle 19 is received and stored in the paint receiving portion 35, so that the spray amount of the sprayed paint is replaced with the paint storage amount in each paint receiving portion 35. Although the presence or absence of the injection abnormality is determined by measuring the paint storage amount, the measurement of the injection amount may be performed by, for example, transporting a dummy building board onto the transport path 13, On the dummy building board surface, the spray paint of each spray nozzle 19 is sprayed with the spray timing shifted so as not to overlap with each other, and a certain pattern is painted for each spray nozzle 19, and it is imaged by an imaging device. By measuring the area of the coating pattern for each spray nozzle 19, the presence or absence of a spray abnormality may be determined.

In addition, the present invention is not limited to the ink jet type coating apparatus, but may be applied to other spray type coating apparatuses such as a spray coating apparatus and the like. It is possible to carry out various changes without departing from the gist of the present invention, such as moving below the injection nozzle 19 only at the time of measurement, or appropriately changing the shapes of the paint receiving unit 32 and the paint receiving portion 35. Needless to say.

[0062]

As is apparent from the above description, according to the injection abnormality judging system for a building board coating apparatus according to the first aspect of the present invention, the injection amount of the paint injected from the injection nozzle is measured and the injection amount is measured. Since the presence or absence of abnormal injection is determined based on the measurement result of the amount, it is possible to automatically detect the abnormal injection of the injection nozzle that causes the coating failure of the building board, and the defective painted plate is painted as in the past. Until an injection abnormality is detected in the inspection process on the downstream side of the line, no abnormal injection is found, and a large number of defective paint plates are not produced. In addition, since there is no individual difference as in a conventional visual inspection, it is possible to accurately detect an abnormal injection and to ensure the coating quality of a building board. Moreover, by measuring the amount of paint sprayed for each spray nozzle or for each spray nozzle, it is possible to grasp the spray state of each spray nozzle or each spray nozzle. Can be specified, and measures can be taken promptly.

According to the second aspect, the paint sprayed from the spray nozzle is received by the paint receiving section, and the spray quantity of the sprayed paint is measured by replacing the spray quantity with the paint stock quantity. Can be measured.

Further, in the third aspect, the state of the paint storage in each paint receiving section is imaged by an image pickup device, and the injection amount is measured by using image processing technology. Easy.

According to the fourth aspect of the present invention, since each paint receiving portion is disposed below the transport path so as not to hinder the transport of the building board or the spraying of the paint on the surface of the building board, the respective paint receiving sections are arranged when the building board passes. There is no need to move the position of the paint receiver. Moreover, the rotation drive means rotates each paint receiving portion downward,
Since the paint in each paint receiving part is automatically discharged, it is possible to save the labor for the operator to discharge the paint in each paint receiving part every time the paint injection amount is measured. Further, by collecting the discharged paint, the paint can be reused.

On the other hand, in claim 5, each time a predetermined number of building boards are painted, the injection amount of the spray nozzle is measured before the next building board reaches the painting position, and it is determined whether or not the spraying is abnormal. Even during the operation of the line, it is possible to periodically check for the presence or absence of the injection abnormality without hindering the painting of the building board or reducing the transport speed of the painting line.

According to the present invention, the coating stop means automatically stops the coating of the building board when the injection abnormality of the injection nozzle is detected, so that the number of defective coatings caused by the injection abnormality is minimized. And the yield of building boards can be prevented from lowering.

According to the seventh aspect of the present invention, the alarm means is activated when an abnormal injection of the injection nozzle is detected. Therefore, the alarm operation can surely inform the worker at the site that the abnormal injection has occurred.

In addition, since the abnormality information output means outputs the information of the injection abnormality, the specific situation of the injection abnormality of the injection nozzle can be grasped in detail, and the cause investigation and the planning of the repair and the like can be performed. And the maintenance is improved.

[Brief description of the drawings]

FIG. 1 is a side view of an injection amount measuring apparatus showing an embodiment of the present invention and essential parts around the injection amount measuring apparatus.

FIG. 2 is a front view of the ink jet type coating apparatus.

FIG. 3 is a perspective view of a paint receiving unit.

FIG. 4 is a block diagram showing an electrical configuration of an injection abnormality determination system.

FIG. 5 is a flowchart showing a control flow of a first controller.

FIG. 6 is a flowchart showing the flow of test injection control.

FIGS. 7A to 7F are diagrams showing examples of a paint storage state in a paint receiving unit;

FIG. 8 is a flowchart showing a flow of operation control of a third controller (part 1);

FIG. 9 is a flowchart showing a flow of operation control of a third controller (part 2);

FIG. 10 is a flowchart showing a flow of operation control of a third controller (part 3);

FIG. 11 is a diagram illustrating an image processing method.

FIG. 12 is a diagram for explaining a method of determining the presence / absence of abnormal injection;

FIG. 13 is a diagram illustrating an example of ejection abnormality information printed out.

FIG. 14 is a flowchart showing a flow of operation control of a second controller;

[Explanation of symbols]

11: Building board, 12: Ink jet type coating device, 13
... Conveying path, 14 ... Conveying roller, 15 ... Coating unit, 1
6 ... Painting head, 17 ... Solenoid valve array, 18 ... Nozzle array, 19 ... Injection nozzle, 20 ... Solenoid valve, 23 ... Paint tank, 24 ... Paint supply pipe, 25 ... Compressor, 26
... pressure adjustment valve, 27 ... paint recovery tank, 28 ... paint return pipe, 29 ... flow rate adjustment valve, 30 ... pump, 31
... Injection amount measuring device (injection amount measuring means), 32 ... Paint receiving unit, 35 ... Paint receiving portion, 36 ... Pulse motor (rotation driving means), 41 ... Potentiometer, 42 ... Digital camera (imaging device), 43 ... Lighting lamp, 45, 46
... photoelectric switch, 47 ... first controller, 48 ... second
Controller (rotation control means), 49: third controller, 51: monitor display, 52: printer, 53
... alarm buzzer (alarm means), 54 ... alarm lamp (alarm means).

Claims (8)

[Claims] 1. A building board for judging whether or not there is a jetting abnormality in a building board coating apparatus that sprays paint from a plurality of spray nozzles arranged above the surface of a building board conveyed on a conveyance path to perform coating. In the injection abnormality determination system of the coating apparatus, based on a measurement result of the injection amount measuring unit and the injection amount measuring unit that measures the injection amount of the paint injected from the injection nozzle for each of the injection nozzles or for each of the plurality of injection nozzles. An injection abnormality judging system for a building board coating apparatus, comprising: an injection abnormality judging means for judging the presence or absence of an injection abnormality. 2. The injection amount measuring means according to claim 1, wherein the injection amount is measured by the injection nozzle when the injection amount is measured.
A plurality of paint receiving units for receiving the paint separately for each book or a plurality of paints, and a storage amount measuring means for measuring the amount of the paint stored in each paint receiving unit; 2. The injection amount is measured.
Injection abnormality determination system for a building plate coating apparatus according to item 1. 3. The storage amount measuring means captures an image of a paint storage state in each of the paint receiving units, and processes an image signal output from the imaging device to store the paint storage amount in each of the paint receiving units. 3. An injection abnormality determination system for a building board coating apparatus according to claim 2, further comprising: an image processing means for measuring the temperature of the building. 4. Each of the paint receivers is disposed below the transport path, and is configured to rotate and drive each of the paint receivers, and to measure a paint storage amount in each of the paint receivers. 4. A rotating control means for operating the rotating drive means to rotate each of the paint receiving parts downward to discharge the paint in each of the paint receiving parts. Injection abnormality determination system for a building plate coating apparatus according to item 1. 5. The injection amount measuring means measures the injection amount of the injection nozzle before the next building board reaches the coating position every time a predetermined number of building boards are painted, and the injection abnormality is measured each time the building board is painted. The system according to claim 1, wherein the determination unit determines whether or not the injection nozzle is abnormal. 6. A coating stop means for stopping coating of a building board when the injection abnormality determination means detects an injection abnormality of any of the injection nozzles.
The injection abnormality determination system for a building board coating apparatus according to any one of claims 1 to 5. 7. The building board according to claim 1, further comprising an alarm unit that performs an alarm operation when the injection abnormality determination unit detects an injection abnormality of any of the injection nozzles. Inspection abnormality determination system for coating equipment. 8. The apparatus according to claim 1, further comprising abnormality information output means for outputting information on the abnormal injection when the abnormal injection determining means detects abnormal injection of any of the injection nozzles. An injection abnormality determination system for a building board coating apparatus according to any one of the above.