KR20160084542A - Apparatus and method for sealing hotmelt of housing - Google Patents

Abstract

According to the present invention, an apparatus for coating a housing with a hot melt adhesive comprises: a robot; a vision module installed on the robot to scan the housing along a movement of the robot; a hot melt adhesive discharging unit installed on the robot to discharge the hot melt adhesive to the housing according to the movement of the robot; and a coating control module generating data of an overall housing shape by scanning the housing through the vision module, acquiring a deformation amount of the housing based on the data of the overall housing shape, correcting a coating route for the coating of the hot melt adhesive, based on the acquired modification amount, and coating the housing with the hot melt adhesive by transmitting the corrected coating route to the robot. According to the present invention, the present invention provides an apparatus for coating a housing with a hot melt adhesive, which prevents a hot melt adhesive coating error in advance.

Description

[0001] APPARATUS AND METHOD FOR SEALING HOT MELT OF HOUSING [0002]

The present invention relates to an apparatus and a method for applying a hot-melt to a housing, and more particularly, to an apparatus and a method for applying a hot-melt to a housing for measuring an amount of deformation of a housing and correcting an application path of the hot-

Generally, a vehicle provides a lighting function to identify an object in a driving direction at night driving, and has a head lamp for notifying other vehicles or other road users of the running state of the vehicle. Such a vehicular headlamp includes a light source such as a halogen lamp or a high intensity discharge (HID) lamp.

On the other hand, Hot Melt is a solvent-free type adhesive that does not use solvent unlike solvent type adhesive which is most used in the industrial field. It is easy to improve working environment and to reduce manpower of work process. Since the automation work is easy, the importance thereof is increasing.

These hot melts are currently used in the automotive industry as well as being used in various areas such as car seats, cable fixing to car roof tiles, carpet bonding, foam materials, smart keys, filter bonding and also in the housing of headlamps .

However, conventionally, when hot melts are applied to the housing, the deformation of the housing is not inspected beforehand, so that the defective and deformed housing is supplied to a post-process, resulting in a process failure.

In addition, conventionally, even when the housing is deformed, the six-axis robot applies hotmelt according to a predetermined coating path to cause defective application of hotmelt, and problems such as tip and housing damage occur.

The background art of the present invention is disclosed in Korean Patent Registration No. 10-0348453 (Apr. 24, 2004).

The present invention has been made to solve the above problems, and an object of the present invention is to provide a hot-melt coating device for a housing, which measures a deformation amount of a housing and corrects an application path of a hot- And a method thereof.

Another object of the present invention is to provide an apparatus and a method for applying a hot-melt coating to a housing for preventing a process failure at the time of producing a headlamp by preventing the introduction of the over-deformed housing to a post-process.

It is still another object of the present invention to provide a hot melt coating apparatus and method for a housing that prevents hot melt such as tip and housing breakage by applying a compensated coating path even when the housing is deformed, .

According to an aspect of the present invention, there is provided a hot melt application apparatus for a housing, comprising: a robot; A vision module installed in the robot and scanning the housing according to movement of the robot; A hot melt discharge unit installed in the robot for discharging hot melt to the housing in accordance with movement of the robot; And a controller for controlling the housing to scan the housing through the vision module to generate overall shape data of the housing, to obtain a deformation amount of the housing on the basis of the overall shape data, to correct the coating path for hot- And a dispensing control module for transferring the corrected dispensing route to the robot and applying hot melt to the housing.

In the present invention, the robot is a six-axis robot movable in x-axis, y-axis, z-axis, rx-axis, ry-axis and rz-axis.

In the present invention, the vision module includes a laser generator for irradiating the housing with a laser; A first camera for photographing the housing to acquire first laser profile data when the laser is irradiated by the laser generator; And a second camera for photographing the housing and acquiring second laser profile data when the laser is irradiated by the laser generator, wherein the first camera acquires the first laser profile data and the second laser profile data at predetermined positions To the coating control module.

In the present invention, the application control module generates the overall shape data by combining the first laser profile data, the second laser profile data, and the trigger signal of the robot.

In the present invention, the application control module may acquire the deformation amount based on an error between the whole shape data and predetermined reference data.

In the present invention, the application control module compares the whole shape data with the reference data, and corrects the application path depending on whether the amount of deformation is within a predetermined set deformation amount.

In the present invention, the coating control module corrects the coating path if the deformation amount is within the set deformation amount.

In the present invention, the application path includes a plurality of path points converted into position values of the robot.

In the present invention, the application control module determines whether the deformation amount is within the set deformation amount for each of the path points, and corrects the application path according to a determination result.

In the present invention, when the deformation amount deviates from the set deformation amount, the housing is subjected to NG processing.

According to an aspect of the present invention, there is provided a method of applying a hot melt to a housing, the method comprising: scanning a housing according to motion of a robot; Generating overall shape data of the housing using data acquired by the application control module through the vision module; Wherein the application control module obtains a deformation amount of the housing based on the overall shape data; The application control module correcting an application path for hot-melt application based on the amount of deformation; And a step in which the robot moves along the application path and the hot-melt applying unit discharges the hot-melt.

In the present invention, the whole shape data is generated by combining the first laser profile data, the second laser profile data, and the trigger signal of the robot.

In the present invention, the deformation amount is acquired on the basis of an error between the whole shape data and predetermined reference data.

In the present invention, the step of correcting the coating path compares the whole shape data with the reference data, and corrects the coating path depending on whether the amount of deformation is within a preset set amount of deformation.

In the present invention, the step of correcting the coating path may correct the coating path if the amount of deformation is within the set deformation amount.

In the present invention, the application path includes a plurality of path points converted into position values of the robot.

In the present invention, the step of correcting the coating path may be performed for each of the path points to determine whether the amount of deformation is within the set deformation amount, and to correct the coating path according to a determination result.

The present invention is further characterized in that when the deformation amount deviates from the set deformation amount, the application control module performs NG processing on the housing.

The present invention measures the amount of deformation of the housing and corrects the application path of the hotmelt based on the measured deformation amount, thereby preventing defective hotmelt coating.

The present invention prevents the introduction of the over-deformed housing to a post-process, thereby preventing a process failure at the time of producing the head lamp.

According to the present invention, even when the housing is deformed, hot melts are applied according to a corrected path to prevent tip and housing breakage, and to prevent process defects such as defective airtightness.

1 is a block diagram of a hot-melt coating apparatus for a housing according to an embodiment of the present invention.
Figure 2 is an illustration of a robot and vision module in accordance with an embodiment of the present invention.
3 is a configuration diagram of a hot-melt applying unit according to an embodiment of the present invention.
4 is a diagram illustrating a TCP (Tool Center Position) setting example of a hot melt application unit according to an embodiment of the present invention.
5 is a diagram illustrating a TCP setting of a vision module according to an exemplary embodiment of the present invention.
6 is a diagram illustrating calibration of a vision module according to an embodiment of the present invention.
7 is a diagram illustrating a scan path teaching process for a housing according to an embodiment of the present invention.
8 is a diagram illustrating a channel according to an embodiment of the present invention.
FIG. 9 is a diagram illustrating scan results of the channel portion of FIG. 8. FIG.
10 is a view showing a range map of a housing according to an embodiment of the present invention.
11 is a view showing the overall shape data of the housing according to an embodiment of the present invention.
12 is a diagram illustrating an example of measurement of a position value and a rotation amount based on reference data according to an embodiment of the present invention.
13 is a diagram illustrating a process of calculating a new route point according to an embodiment of the present invention.
14 is an exemplary view showing a position value of a robot path point corrected by a deformation amount according to an embodiment of the present invention.
15 is a view showing path points of a robot according to an embodiment of the present invention.
16 is a flowchart of a method of applying a hotmelt to a housing according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an apparatus and a method for applying a hotmelt to a housing according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings. In this process, the thicknesses of the lines and the sizes of the components shown in the drawings may be exaggerated for clarity and convenience of explanation. Further, the terms described below are defined in consideration of the functions of the present invention, which may vary depending on the user, the intention or custom of the operator. Therefore, definitions of these terms should be made based on the contents throughout this specification.

FIG. 1 is a block diagram of a hot-melt coating apparatus for a housing according to an embodiment of the present invention. FIG. 2 is an exemplary view of a robot and a vision module according to an embodiment of the present invention. FIG. 4 is a view illustrating an example of a TCP (Tool Center Position) setting of a hot melt application unit according to an embodiment of the present invention. FIG. 5 is a view illustrating a TCP (Tool Center Position) setting of a vision module according to an exemplary embodiment of the present invention. 6 is a diagram illustrating calibration of a vision module according to an embodiment of the present invention. FIG. 7 is a view illustrating a scan path teaching process for a housing according to an embodiment of the present invention, FIG. 8 is a view illustrating a channel according to an embodiment of the present invention, FIG. 9 is a view illustrating a scan result of the channel portion of FIG. 8, and FIG. 10 is a view showing a range map of a housing according to an embodiment of the present invention. Fig. FIG. 11 is a view showing overall shape data of a housing according to an embodiment of the present invention. FIG. 12 is a view illustrating an example of measuring a position value and a rotation amount based on reference data according to an embodiment of the present invention FIG. 13 is a diagram illustrating a process of calculating a new route point according to an embodiment of the present invention. FIG. 14 is an exemplary view showing a position value of a robot route point corrected by a deformation amount according to an embodiment of the present invention And FIG. 15 is a diagram illustrating path points of a robot according to an embodiment of the present invention.

Referring to FIG. 1, a hot-melt dispensing apparatus for a housing according to an embodiment of the present invention includes a robot 10, a vision module 20, a hot-melt dispensing unit 30, and a dispensing control module 40.

Referring to FIG. 2, the robot 10 scans the housing through the vision module 20 and moves in various directions so that the hot-melt discharging portion 30 can apply hot-melt to the housing. The robot 10 may be a six-axis robot 10 that is movable in the x-, y-, z-, rx-, ry-, and rz-axis directions.

The vision module 20 is installed in the robot 10 and transmits the scanned data to the application control module 40 by scanning the housing according to the movement of the robot 10. [ The vision module 20 includes a first camera 21, a second camera 22, and a laser generator 23.

The laser generator 23 irradiates the housing with a line laser and the first camera 21 takes the first laser profile data by photographing the housing when the laser is irradiated by the laser generator 23, When the laser is irradiated by the laser generator 23, the camera 22 photographs the housing to acquire the second laser profile data. The laser generator 23, the first camera 21, and the second camera 22 are driven in synchronism with each other.

As shown in FIG. 3, the hot melt discharge unit 30 is installed in the robot 10 and discharges hot melt to the housing according to the movement of the robot 10, thereby applying hot melt to the housing.

The vision module 20 and the hot melt discharge unit 30 are respectively installed in the robot 10 and each is switched by the robot 10 to perform a unique operation and selected by a method such as pneumatic control Lt; / RTI >

The robot 10, the vision module 20, the hot melt discharge unit 30, and the application control module 40 are connected to each other through Ethernet communication, I / O communication, and the like, and can exchange data with each other. Here, the communication method is not limited to the above-described embodiment, and may be variously selected depending on the communication environment of the workplace.

The application control module 40 controls the robot 10 to scan the housing through the vision module 20 to generate the overall shape data of the housing and calculate the total shape data based on the error between the generated total shape data and the preset reference data, And generates a sealing path based on the amount of deformation. Then, the application control module 40 compares the acquired deformation amount with a preset set deformation amount, corrects the application path for hot-melt application according to the comparison result, and transmits the corrected application path to the robot 10. Accordingly, the robot 10 moves along the application path, and the hot-melt discharging unit 40 discharges the hot-melt to the housing to apply the hot-melt.

Here, the reference data is total shape data set based on a housing without deformation, and is data that serves as a reference for determining whether the deformation amount of the housing and the deformation incidence are within a set deformation amount.

In order to obtain such reference data, the origin of the hot melt discharging unit 30 and the vision module 20 are first calibrated.

In other words, the distance and angular values (x, y, z, rx, ry, rz) from the robot flange to the hot melt discharging portion 30 are set in the hot melt discharging portion 30 as shown in FIG. The distances and angles to the hot melt dispenser 30 are set based on the pre-stored production drawings, and can be set using the robot tool center position (TCP) function.

5, the distance and angle values (x, y, z, rx, ry, rz) between the vision modules 20 in the robot flange are set. In this case, ) Can be set by adding the W / D distance value to the predetermined manufacturing drawing reference.

6, the laser is irradiated while the calibration module 20 and the calibration target are kept parallel through the first camera 21 and the second camera 22 of the vision module 20, In this case, adjust the tilt so that the center of the top surface of the calibration target is located at the center of the image. After obtaining the laser images of the left and right cameras, the AQSENSESAL 3D library is subjected to static calibration to acquire calibration data.

After the origin of the hot melt discharging unit 30 and the vision module 20 is calibrated as described above, the robot is taught to scan the housing by using the vision module 20 and to discharge the hot melt. The robot teaching process includes a scan path teaching process for the vision module 20 to scan the housing and a dispense path teaching process for the hot melt dispensing unit 30 to dispense the hot melt to the housing.

7 and 8, the top and bottom surfaces of the channel are clearly visible, and the bottom surface of the channel portion and the vision module 20 are perpendicular to each other. And the channel bottom surface is always positioned at the same position on the image. 9 shows data corresponding to the shapes of the top and bottom surfaces of the channel when the channel unit of the housing is scanned by the vision module 20 to generate reference data.

Then, the teaching process is performed according to the criteria shown in Table 1 below.

Standard for hot-melt application path teaching Item Explanation speed V = average 100 mm / s Coating angle Maintain a minimum of 20 ° Application height 5mm on the bottom Overlap Application start to completion overlap interval: 15 mm Inflection point There should be no excessive rotation on the robot side (within 10 rotation of 10mm movement standard) Foreign matter Robot and hose Interference Robot Motion removal

When the hot-melt discharging portion 30 applies hot-melt on the basis of the above-described Table 1, the moving speed of the hot-melt discharging portion 30 which influences the application amount of the hotmelt, and the moving speed of the hot- The application height of the hot melt application portion 30 which influences can be additionally adjusted.

On the other hand, when the reference data is generated as described above, the application control module 40 newly corrects the deformation amount and the application path based on the reference data.

More specifically, the application control module 40 controls the vision module 20 to obtain the first laser profile data acquired by the first camera 21 acquired at the same time in the process of scanning the housing, The second laser profile data acquired by the camera 22, and the trigger signal of the robot 10 to generate the overall shape data.

In this case, the first laser profile data, the second laser profile data, and the trigger signal are respectively collected at the same time, and each time corresponds to the path point of the reference data set for the housing, that is, the position value of the robot 10 Respectively. That is, every time the robot 10 moves and reaches the above-mentioned path point, the application control module 40 outputs the first laser profile data, the second laser profile data, and the trigger signal And generates the entire shape data by using them.

The application control module 40 generates a range map (Rangemap) as shown in FIG. 10 using the trigger signal, the first laser profile data, the trigger signal, and the second laser profile data, And merges the obtained range maps to generate 3D shape data for the housing as shown in FIG.

When the overall shape data is generated as described above, the application control module 40 acquires the deformation amount based on the error between the reference data set as described above and the entire shape data (sample 1 in FIG. 12) as shown in FIG.

That is, the application control module 40 measures the x position value, the y position value, the z position value, and the rx rotation amount, the ry rotation amount, and the rz rotation amount of the overall shape data, Calculate the channel center line (brown line) of the data, and draw a circle (green circle) with the robot teaching reference (brown straight line) of the reference data as the origin. Then, the application control module 40 calculates the position of the contact where the circle contacts the channel center line (brown line). In this case, the contact point tangent to the circle and the channel center line (brown line) is the path point of the newly corrected application path, and each of the path points of the application path can be newly corrected.

When the path point is acquired in this manner, the application control module 40 sorts the deformation amount acquired by acquiring the deformation amount for each path point, as shown in Fig. 14, and stores the deformation amount calculated for each path point in a predetermined setting When the deformation amount of each path point is out of the predetermined set deformation amount as a result of the comparison, the housing is NG processed and discharged from the process line.

On the other hand, if the amount of deformation obtained for each path point is within a predetermined set deformation amount, the application control module 40 delivers the application path, that is, the path point shown in Fig. 15, to the robot 10. In this case, the path point is generated based on the data acquired on the basis of the vision module 20, that is, the vision coordinate system value of the vision module 20, and converted into the robot coordinate system value, which is an absolute coordinate system value. To this end, the application control module 40 converts the non-coordinate system value into the robot coordinate system value using the tool matrix T as shown in Equation (1) below. In this case, the rotation is converted into z, y,

That is, the application control module 40 obtains the robot coordinate system value by the following equation (2).

Here, P _robot is the robot coordinate system value, T is the tool matrix, and P _vision is the vision coordinate system value.

Meanwhile, after the application path is created as described above, the application control module 40 transfers the application path to the robot 10, and the robot 10 stores the application path as position variables Corrects the application path, and moves according to the corrected application path so that hot melts can be applied to the housing.

Hereinafter, a method of applying a hotmelt to a housing according to an embodiment of the present invention will be described in detail with reference to FIG.

Referring to FIG. 16, the application control module 40 controls the robot 10 to scan the housing through the vision module 20 to generate overall shape data of the housing (S10).

More specifically, the vision module 20 scans the housing according to the movement of the robot 10, and transmits the scanned data, that is, the first laser profile data and the second laser profile data to the application control module 40 , The robot 10 transmits a trigger signal to the application control module 40.

Then, the application control module 40 generates a range map using the trigger signal, the first laser profile data, the trigger signal, and the second laser profile data, respectively, and merges the generated range maps to the housing And generates total shape data in the form of a 3D (Dimension).

When the overall shape data is generated as described above, the application control module 40 newly generates a path point based on the error between the whole shape data and the reference data, and confirms the amount of deformation for each generated path point (S20).

Then, the application control module 40 compares the deformation amount of each path point with a predetermined deformation amount, and determines whether or not the deformation amount deviates from the predetermined deformation amount for each path point (S30).

As a result of the determination in step S30, if the deformation amount deviates from the predetermined deformation amount for each path point, the housing is NG processed (S60) and discharged from the process line.

On the other hand, if the amount of deformation is within the set deformation amount for each path point, the application control module 40 delivers the application path to the robot 10 (S40). In this case, the application control module 40 converts the vision coordinate value of the path point, that is, the vision module 20, into the robot coordinate system value, which is an absolute coordinate system value, and transfers the robot coordinate system value to the robot 10.

Accordingly, the robot 10 stores the coating path in the form of position variables, corrects the coating path, and moves according to the corrected coating path. At this time, the hot-melt discharging part 30 discharges the hot- (S50).

In this embodiment, the deformation amount of the housing is measured and the application path of the hot-melt is corrected based on the measured deformation amount to prevent the hot-melt coating failure in advance.

In addition, the present embodiment selectively filters the over-deformed housing to prevent the introduction of the deformed housing into a subsequent process, thereby preventing a process failure at the time of producing the head lamp.

In addition, in this embodiment, even when the housing is deformed, hot melts are applied in accordance with the corrected path to prevent breakage of tips and housings, thereby preventing process defects such as air tightness.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, I will understand. Accordingly, the true scope of the present invention should be determined by the following claims.

10: Robot
20: Vision module
21: First camera
22: Second camera
23: Laser generator
30: Hot melt discharge part
40: dispensing control module

Claims (18)

robot;
A vision module installed in the robot and scanning the housing according to movement of the robot;
A hot melt discharge unit installed in the robot for discharging hot melt to the housing in accordance with movement of the robot; And
The housing is scanned through the vision module to generate the overall shape data of the housing, the deformation amount of the housing is obtained on the basis of the overall shape data, and the coating path for hot-melt coating is corrected based on the obtained deformation amount And a dispensing control module for transferring the corrected dispensing route to the robot and applying hot melt to the housing.
The apparatus according to claim 1, wherein the robot is a six-axis robot movable in x-axis, y-axis, z-axis, rx-axis, ry-axis, and rz-axis.
2. The apparatus of claim 1, wherein the vision module
A laser generator for irradiating the housing with a laser;
A first camera for photographing the housing to acquire first laser profile data when the laser is irradiated by the laser generator; And
And a second camera for photographing the housing and acquiring second laser profile data when the laser is irradiated by the laser generator,
Acquires the first laser profile data and the second laser profile data at predetermined positions, and transfers the acquired data to the application control module.
4. The apparatus of claim 3, wherein the application control module
Wherein the first shape data, the second profile data, and the trigger signal of the robot are combined to generate the overall shape data.
The apparatus according to claim 1, wherein the application control module obtains the deformation amount based on an error between the overall shape data and predetermined reference data.
6. The apparatus according to claim 5, wherein the application control module compares the overall shape data with the reference data and corrects the application path according to whether the amount of deformation is within a predetermined set deformation amount.
7. The hot-melt coating apparatus according to claim 6, wherein the coating control module corrects the coating path if the deformation amount is within the set deformation amount.
[8] The apparatus of claim 7, wherein the application path includes a plurality of path points converted into position values of the robot.
The hot-melt coating apparatus according to claim 8, wherein the application control module determines whether the deformation amount is within the set deformation amount for each of the path points, and corrects the application path according to a determination result.
7. The apparatus of claim 6, wherein the application control module
And when the deformation amount deviates from the set deformation amount, the housing is subjected to NG processing.
The vision module scanning the housing according to the movement of the robot;
Generating overall shape data of the housing using data acquired by the application control module through the vision module;
Wherein the application control module obtains a deformation amount of the housing based on the overall shape data;
The application control module correcting an application path for hot-melt application based on the amount of deformation; And
Wherein the robot moves along the application path and the hot-melt application unit discharges the hot-melt.
12. The method according to claim 11,
Wherein the first laser profile data, the second laser profile data, and the trigger signal of the robot are combined to generate the first laser profile data, the second laser profile data, and the trigger signal of the robot.
12. The method according to claim 11,
Wherein the hot-melt application method is obtained based on an error between the whole shape data and predetermined reference data.
14. The method of claim 13, wherein correcting the application path
And comparing the overall shape data with the reference data to correct the coating path depending on whether the amount of deformation is within a preset set amount of deformation.
15. The method of claim 14, wherein correcting the dispensing path comprises:
And corrects the coating path if the deformation amount is within the set deformation amount.
16. The method of claim 15, wherein the application path includes a plurality of path points converted into position values of the robot.
17. The method of claim 16, wherein correcting the dispensing path comprises:
Determining whether the deformation amount is within the set deformation amount for each of the path points, and correcting the coating path according to a determination result.
15. The method of claim 14, further comprising, when the amount of deformation is out of the set deformation amount, causing the application control module to perform an NG process on the housing.

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