KR20190028213A - Smart Monitoring System and Painting System thereby - Google Patents

Abstract

According to the present invention, a smart monitoring system (1) applied to a painting system (100) comprises: two or more cameras (10-1, 10-2) for photographing first and second painting robots (5-1, 6-1) of a painting booth (3) with real-time image data; an image distributor (21) for distributing the image data; an image analyzer (23) for performing image conversion to DVR and transmission and reception; a computer (30) for generating a high-quality image of the image data, a defect check image of a painting process, and a process status display image marked by ″OK″ or ″NG″ with artificial intelligence software (31); a monitor (41) or a mobile phone (43) for indicating whether there is a defect, such as ″OK″ or ″NG″, while playing the high quality image for the painting process; and a wireless network (200) for limiting wireless communication to the installation space of the painting booth (3). As a result, in the painting system, real-time monitoring of the painting process is performed. Particularly, preventive quality and predictive preservation of the first and second painting robots (5-1, 6-1) are performed, a clear cause for spray pattern defects, conveyor surging, and door opening is determined, and a quick response is achieved.

Description

[0001] Smart Monitoring System and Painting System [

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a monitoring system, and more particularly, to a painting system in which smart monitoring is performed using artificial intelligence technology in a painting operation image.

In general, the coating process of coating line equipment is a process in which the liquid surface is spread on the surface of the object to form a thin layer, thereby protecting and coloring the object surface. It is very important to prevent quality defects after coating.

For this purpose, the painting process automates the coating process by the coating robot and the automation of the coating quality control by the robot monitoring system.

For example, the robot monitoring system is installed on a painting line and is constituted by an image camera for photographing a painting robot and an image monitor for checking a photographed image in real time, so that a paint job is managed by visualizing the operation of the painting robot.

Particularly, the above-mentioned shot image is utilized for clear cause analysis for poor coating quality due to image storage using a storage medium, and is shared via a mobile phone (or smart phone) wirelessly, Do.

Korean Patent Publication No. 10-2005-0069067 (Jul. 2005)

However, the robotic monitoring system can only be used by monitoring the availability of the photographed images in real time.

For example, the robot monitoring system described above detects an abnormal situation such as a spray pattern failure of a painting robot, a conveyor surge for conveying a painted object, a door of a painting booth, etc., as an image taken by an operator, .

In particular, the post-management of the coating process can not be avoided. First, it is a predictive task constraint. This is due to the inability to check the correct operation state at the time of regular inspection, and the inconveniences and the work load after the occurrence of the failure. Second, it is insufficient to establish a countermeasure for preventing recurrence. This is due to the difficulty in analyzing the cause of paint robot collision and LOT failure, the uncertainty of vision (glass window contamination) and body interference, This is caused by the impossibility of clear checking due to restrictions. Third, safety accidents are a concern, due to excessive inspections caused by entry into the booth.

In view of the above, the present invention is capable of preserving quality and prediction of a painting robot by performing image analysis and judgment of a painting robot based on image capture of an artificial intelligence and motion recognition of an image of a painting line, and The object of the present invention is to provide a smart monitoring and painting system capable of promptly recognizing the causes of spray pattern defects, conveyor surging and door opening, and quickly coping with real-time monitoring of painting operations by real-

According to another aspect of the present invention, there is provided a smart monitoring system comprising: a picture taking module for acquiring a painting process as a real-time photographed image; An image processing module communicating with the image capturing module and receiving the captured image as image data in real time; Wherein the image processing module is connected to the image processing module in communication with the image processing module and transmits / receives the image data to / from the image processing module, and generates an abnormal image according to the real time analysis and determination of the abnormality of the painting process from the high- A computer equipped with an artificial intelligence software for generating a process status display image by storing an analysis history and capturing a screen image; A video output module communicatively coupled to the computer and the image processing module to receive and reproduce the high-definition image and the process status display image, respectively; A wireless communication device that forms the communication link as a wireless network; Is included.

In a preferred embodiment, the artificial intelligence software of the computer is divided into a library and a main program and an application program; Wherein the library performs the conversion of the motion image by software of a motion recognition engine of the motion recognition engine and the conversion of the high-definition image into an image capture software (S / W) of an image capture engine, The application program analyzes and verifies the presence / absence of abnormality of the painting process in the motion recognition image with S / W (Software), and the output, the analysis history storage and the screen capture are performed by the application software .

As a preferred embodiment, the main program may include a spray pattern recognized as the presence or absence of a coating liquid discharge and a discharge pattern width, a conveyor surging recognized as a position of a coating object to be charged in the coating process, And the presence or absence of the abnormality of the painting process is judged by opening the door recognized by the angle.

In a preferred embodiment, the image capturing module is composed of first and second cameras with explosion-proof authentication. Wherein the image processing module comprises: an image processor for receiving the image data from the image capturing module and transmitting the image data to the computer; and a controller for transmitting the high-definition image, the motion recognition image, And an image analyzer that sends and receives data to and from the computer. The video output module includes a screen reproduction monitor, a tablet, and a portable mobile phone. The wireless communication device forms a WiFi wireless network.

According to another aspect of the present invention, there is provided a coating system comprising: an image capturing module for capturing a coating process in real time as image data; an image processing module for receiving the image data; A computer equipped with an artificial intelligence software for generating an anomaly image and a process status display image for the coating process, a smart monitoring system comprising a video output module for receiving and reproducing the high quality image and the process status display image, respectively; A painting booth in which the first and second painting robots for painting the painted body conveyed by the conveyor are installed, and the imaging module is installed inside; A wireless network for limiting wireless communication for transmission and reception of the smart monitoring system to an installation space of the painting booth; Is included.

In a preferred embodiment, the painting booth is a painting upper booth in which an inner plate of the painting body is painted.

The smart monitoring painting system according to the present invention realizes the following actions and effects by processing a painting operation image with artificial intelligence of smart monitoring.

First, real - time image analysis and judgment based on artificial intelligence based on real - time monitoring painting image are performed to prevent quality and prediction of painting line. Second, productivity is improved by ensuring uniform painting quality, preventing defects and failures in advance. Third, the reprocessing rate is lowered by the optimal painting quality maintenance by the pattern of painting operation and teaching operation image data. Fourth, the prevention of LOT failure and the failure rate of equipment are lowered by securing the predictive integrity through comparative analysis in addition to the utilization of image data. Fifth, it is possible to extend the replacement period of the bell disk by establishing precautions to prevent recurrence by precise cause analysis in case of a collision with the painting robot and the painting target or painting equipment. Sixth, the work efficiency is improved with the 0% accident rate by avoiding the inspection through entry of the painting line into the booth.

FIG. 1 is a configuration diagram of a smart monitoring system according to the present invention, FIG. 2 is an example of construction of a coating system to which smart monitoring is applied according to the present invention, and FIG. 3 is a schematic view of a smart monitoring system according to the present invention, FIG. 4 is a spray pattern analysis and judgment state in the artificial intelligence quality control according to the present invention, and FIG. 5 is a state in which spray pattern defects are caused according to the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings, which illustrate exemplary embodiments of the present invention. The present invention is not limited to these embodiments.

Referring to FIG. 1, the smart monitoring system 1 includes an image capturing module 10, an image processing module 20, a computer 30, and a video output module 40.

For example, the image capturing module 10 photographs the interior of the painting booth 3. The image processing module 20 collects and transmits the photographed image as real-time camera image data. The computer 30 analyzes and determines the real-time camera image data and outputs the result as "OK" in a normal state and "NG" in an abnormal or bad state. The image output module 40 displays " OK "or " NG" so that the operator of the painting booth 3 can be managed.

Specifically, the image capturing module 10, the image processing module 20, the computer 30, and the image output module 40 are configured as follows.

The image capturing module 10 is composed of two first and second cameras 10-1 and 10-2, which are explosion-proof certified cameras. The first and second cameras 10-1 and 10-2 perform a painting operation on the object 9 to be painted. (5, 6) is installed. For example, the first camera 10-1 is positioned to photograph a first painting apparatus 5 for performing a painting operation on one side of the painting object 9, the second camera 10-2, Is positioned to photograph a second coating device (6) for performing a coating operation on the opposite side of the coating object (9).

The image processing module 20 includes an image processor 21 and an image analyzer 23. The image analyzer 23 is divided into a video server 23-1 and a mobile server 23-2. For example, the image processor 21 receives the captured images of the first and second cameras 10-1 and 10-2 as real-time camera image data and transmits them to the computer 30. The image server 23-1 receives the image-captured high-quality image from the computer 30 and transmits the analyzed high-quality image to the computer 30 while transmitting the high-quality image to the image output module 40. [ The mobile server 23-2 receives the motion recognition processed motion recognition image from the computer 30 and transmits the motion recognition image to the video server 23-1 and the computer 30, And transmits it to the computer 30 again.

The computer 30 is equipped with an artificial intelligence software 31 that performs high-quality image conversion of real-time camera image data, motion recognition image conversion of a high-quality analysis image, abnormal real-time analysis and judgment, storage of analysis history, do. For example, the artificial intelligence software 31 includes a library 33, a main program 35, and an app program 37.

The library 33 is divided into an image capture engine 33-1 and a motion recognition engine 33-2. The image capture engine 33-1 receives the real-time camera image data of the first and second cameras 10-1 and 10-2 from the image processor 21 and receives the image through the image capture S / Converts the real-time camera image data into a high-quality image by processing, and outputs the converted image to the image server 23-1. The motion recognition engine 33-2 receives the high-resolution analysis image transformed from the high-quality image through the image server 23-1, analyzes it by motion recognition in the image through motion recognition S / W (Software) Converted into a motion recognition image in which the position of the object is provided in real time, and outputs the motion recognition image to the mobile server 23-2 while providing the same to the main program 35. [

The main program 35 functions as a main S / W (Software) including a smart processing engine 35-1. The smart processing engine 35-1 receives a motion Analyzes and judges the abnormality of the painting operation in the recognized image in real time and provides it to the mobile server 23-2 as an abnormal presence image. For example, the smart processing engine 35-1 controls the spray pattern of the first and second painting devices 5 and 6, the conveying of the conveying object 9, the opening of the painting booth 3, Analyze and judge whether there is any abnormality in painting work.

The smart program 37-1 functions as an application S / W (Software) including a smart management engine 37-1 and the smart management engine 37-1 controls an application program A process state display image including a spray pattern, a conveyor surge, a door opening, and the like, and storing the analysis history and capturing the screen, is transmitted to the video output module 40. [ In this case, the process-state display image includes an indication of " OK "or " NG"

The video output module 40 reproduces the high-quality video transmitted from the video server 23-1 and provides an "OK" or "NG" display of the process status display image transmitted from the app program 37, In real time. Particularly, the video output module 40 includes a mobile phone 43 that can be carried along with a monitor 41 installed on a work line, so that an operator can check the work line as well as in real time while moving.

The smart monitoring system 1 is also configured with a wireless communication device 50. The wireless communication device 50 includes first and second cameras 10-1 and 10-2, a video processor 21, a video server 23-1, a mobile server 23-2, a computer 30, (41) and the mobile phone (43) by wireless network to enable wireless communication in a space where the smart monitoring system (1) is installed.

2 illustrates a painting system 100 in which a smart monitoring system 1 is utilized.

2, the painting system 100 is constructed with a smart monitoring system 1, a painting booth 3 and a wireless network 200. [

More specifically, the painting booth 3 includes a coating part booth 3-1, a maintenance part booth 3-2, a painting PCR booth 3-3, and a coating part booth 3-2 on which a conveyor for conveying and stopping the coated body 9-1 is placed. And the coated PM booth 3 to 4. The coating booth 3-1 and the booth booth 3-2 and the coating PCR booth 3-3 and the coated PM booth 3- 4 are provided with first and second coating robots 5-1 and 6-1 for spraying the coating liquid on the stopped coating body 9-1. Therefore, the painting part booth 3-1 is an example of a general painting top booth in which the inner painting of the painting body 9-1 is performed.

Specifically, the smart monitoring system 1 includes the image capturing module 10, the image processing module 20, the computer 30, and the image output module 40, thereby having the same configuration as the smart monitoring system 1 of FIG. 1 Element. The number of the image capturing modules 10 and the image output modules 40 is changed in accordance with the configuration of the painting booth 3 and the system configuration associated with the image processing module 20 and the computer 30 is slightly changed Can be different.

For example, the image capturing module 10 includes four first and second cameras 10-1 and 10-2 installed in a painting booth 3-1, two first cameras 10-1 and 10-2 installed in a booth 3-2, The first and second cameras 10-1 and 10-2 and the first and second cameras 10-1 and 10-2 and the paint PM booth 3-4 installed in the paint PCR booth 3-3, And the first and second cameras 10-1 and 10-2 are installed in the vehicle. Especially, the installation positions of the first and second cameras 10-1 and 10-2 are appropriately changed in accordance with the characteristics of the respective booths 3-1, 3-2, 3-3 and 3-4. The video output module 40 controls the monitor 41 to be connected to the paint booth 3-1, the booth 3-2, the paint PCR booth 3-3, and the paint PM booth 3-4 A total of four monitors 41 and a total of four mobile phones 43 are formed by linking the mobile phone 43 by wireless communication while being fixedly installed on the mobile phone 43. [ In this case, the monitor 41 may be a tablet.

For example, the image processing module 20 includes an image processor 21 and an image analyzer 23. The image processor 21 is connected to each of the first and second cameras 1 to 3 of the paint booth 3-1, the booth 3-2, the paint PCR booth 3-3, 10-1, 10-2) of the real-time camera image data. The image analyzer 23 is composed of a DVR (Digital Video Recorder) in which image conversion and transmission are performed together and functions as a video server 23-1 and a mobile server 23-2. Unlike the library 33 in which the artificial intelligence software 31 including the library 33 and the main program 35 and the application program 37 are equally installed but is associated with the image processor 21, The program 35 and the application program 37 are linked to the DVR type image analyzer 23 without distinguishing between the video server 23-1 and the mobile server 23-2.

Specifically, the wireless network 200 is a network constructed for wireless communication of the smart monitoring system 1 in the painting system 100, similar to the function of the wireless communication device 50. However, since the wireless network 200 is constructed as a closed internal network using Wi-Fi, external connection is not possible. That is, the wireless network 200 limits the wireless communication of the smart monitoring system 1 to the installation space of the painting booth 3.

Referring to FIG. 3, there is illustrated a painting process abnormality item of the painting system 100 performed in the computer 30 using the main program 35 of the artificial intelligence software 31. FIG.

For example, the painting process abnormality item is classified into a spray pattern notification 31-1, a conveyor surging notification 31-2, and a door open notification 31-3. The spray pattern notification 31-1 is provided for each of the paint booth 3-1, the booth booth 3-2, the paint PCR booth 3-3, and the paint PM booth 3-4, Quot; OK "or " NG" with respect to the presence or absence of coating liquid ejection and the width of the ejection pattern of the first and second coating robots 5-1 and 6-1. The conveyor surging notification 31-2 is transmitted to a conveyor installed in each of the painting booth 3-1, the booth booth 3-2, the painting PCR booth 3-3, and the painted PM booth 3-4, Quot; OK "or " NG" for analyzing the position of the painted vehicle body 9-1 to be transported on the vehicle. The door opening notification 31-3 is a door open notification of the doors provided in the painting booth 3-1, the booth booth 3-2, the paint PCR booth 3-3 and the painted PM booth 3-4, It is "OK" or "NG" for open angle analysis.

Referring to FIG. 4, utilization of the smart monitoring system 1 in conjunction with the wireless network 200 in the operation of the painting system 100 is illustrated.

The first and second cameras 12-1 and 10-2 of the twelve cameras 10-1 and 10-2 are connected to a paint booth 3-1, a booth 3-2, a paint PCR booth 3-3, 4 and the spray operation state of the first and second painting robots 5-1 and 6-1 with respect to the painting body 9-1 as real-time camera image data.

Then, the real-time camera image data is collected in real time by the image processor 21, and then is distributed to the paint booth 3-1, the booth 3-2, the paint PCR booth 3-3, (3-4) and sent to the computer 30 and processed in the artificial intelligence software 31. [ Then, the library 33 outputs high-quality image data of the booth-based real-time camera image data to the image analyzer 23 through the image capture engine 33-1. The image analyzer 23 converts each of the high-quality images into a painting booth 3-1, a booth 3-2, a painting PCR booth 3-3, a painting PM booth 3-4, To the motion recognition engine 33-2 while transmitting the high quality analysis image to the monitor 41 and the mobile phone 43 installed in each of the mobile phones. The motion recognition engine 33-2 converts the high-quality analysis image into a motion recognition image in which the position of the analysis target is provided in real time through the motion recognition of the analysis object, and provides the motion recognition image to the main program 35. [

Thereafter, the main program 35 is installed in each of the paint booth 3-1, the booth booth 3-2, the paint PCR booth 3-3, and the paint PM booth 3-4, 2, the paint booth 3-1, the maintenance booth 3-2, the paint PCR booth 3 (3) 3), and determines whether the conveyor is to be thrown by analysis of the body position of the painted body 9-1 carried to the conveyor connected to the painted PM booth 3-4. The painted part booth 3-1, 3-2), a paint PCR booth (3-3), and a paint PM booth (3-4). As a result, the main program 35 is applied to each of the paint booth 3-1, the booth booth 3-2, the paint PCR booth 3-3, and the paint PM booth 3-4, ON "or " NG" of the notification 31-1, the conveyor surging notification 31-2 and the door open notification 31-3 to the image analyzer 23. [ Then, the image analyzer 23 transmits "ON" or "NG" to the application program 37.

The application program 37 then stores the analysis history of "ON" or "NG" for the spray pattern, the conveyor surge, the door opening, etc. and outputs the screen capture to the video output module 40. As a result, the monitor 41 and the mobile phone 43 are connected to the application program 37 and connected to the paint booth 3-1, the booth 3-2, the paint PCR booth 3-3, Quot; NG "for each of the booths 3-4 and the operator displays " NG" for each of the spray pattern, conveyor surge and door opening through the monitor 41 or the mobile phone 43, Immediately by checking the display, the corresponding abnormal condition is handled.

Especially, the operator senses an abnormal operation that the raw main program 35 can not capture even if the display is "ON" through the reproduced output result of the app program 37 via the monitor 41 or the mobile phone 43, The preventive quality and predictive preservation can be performed for each of the coating booth 3-1, the booth booth 3-2, the coating PCR booth 3-3, and the coated PM booth 3-4.

Referring to Fig. 5, an example of " NG "of a spray pattern through utilization of the smart monitoring system 1 is illustrated.

The "NG" example of the spray pattern is a pattern formed on one of the coating part booth 3-1, the maintenance part booth 3-2, the coating PCR booth 3-3 and the coated PM booth 3-4 1 shows a shaping air fitting 7 as an example of the first coating robot 5-1 or the second coating robot 5. The shaping air fitting 7 is a part of the painting body 9-1, Of the clear plate is a phenomenon that causes the shortage of the inner plate, and it is classified as LOT defect and it is necessary to repaint.

Therefore, the painting system 100 is constructed of the hardware of the smart monitoring system 1 and is monitored by an artificial intelligence program, thereby preventing quality and prediction, ensuring uniform painting quality, preventing malfunction and failure, reducing re- It is possible to achieve 0% accident rate by reducing the equipment failure rate, analyzing the exact cause, establishing measures to prevent recurrence clearly, as well as preventing entry into the painting booth.

As described above, the smart monitoring system applied to the coating system according to the present embodiment is a system in which two or more cameras (not shown) for photographing the first and second coating robots 5-1 and 6-1 of the painting booth 3 as real- (10-1, 10-2), an image distributor (21) for distributing image data, an image analyzer (23) for performing image conversion and transmission and reception with DVR, and a high- A computer 30 for generating an abnormal presence / absence image of the coating process and a process status display image marked " OK "or" NG ", a computer 30 for reproducing the high- And a wireless network 200 for limiting the wireless communication to the installation space of the painting booth 3. The monitor 41 or the mobile phone 43 is provided with a wireless network 200, As a result, in the painting system, real-time monitoring of the coating process is performed, and in particular, prevention quality and prediction of the first and second coating robots 5-1 and 6-1 are maintained, and spray pattern defects, conveyor surging and door opening Clear cause identification and prompt response are achieved.

1: Smart Monitoring System
3: Painting booth 3-1: Painting booth
3-2: Maintenance booth 3-3: Painting PCR booth
3-4: Painted PM booth 5,6: 1st and 2nd coating devices
5-1, 6-1: 1st and 2nd paint robots 7: Shaping air fitting
9: Coating object 9-1: Coated body
10: image capturing module 10-1, 10-2: first and second cameras
20: image processing module 21: image processor
23: image analyzer 23-1: image server
23-2: Mobile server
30: Computer 31: Artificial Intelligence Software
31-1: Spray pattern notification 31-2: Conveyor surge notification
31-3: Door open notification 33: Library (Library)
33-1: Image Capture Engine 33-2: Motion Recognition Engine
35: main program 35-1: smart processing engine
37; App Program 37-1: Smart Management Engine
40: video output module 41: monitor
43: mobile phone 50: wireless communication device
100: paint system 200: wireless network

Claims (16)

An imaging module for acquiring a coating process in real time as an imaging image;
An image processing module communicating with the image capturing module and receiving the captured image as image data in real time;
Wherein the image processing module is connected to the image processing module in communication with the image processing module and transmits / receives the image data to / from the image processing module, and generates an abnormal image according to the real time analysis and determination of the abnormality of the painting process from the high- A computer equipped with an artificial intelligence software for generating a process status display image by storing an analysis history and capturing a screen image;
A video output module communicatively coupled to the computer and the image processing module to receive and reproduce the high-definition image and the process status display image, respectively;
A wireless communication device that forms the communication link as a wireless network;
And a smart monitoring system.
The smart monitoring system according to claim 1, wherein the abnormality is outputted as "OK" in the normal state and "NG" in the abnormal or defective state and displayed in the video output module.
The smart monitoring system according to claim 1, wherein the artificial intelligence software of the computer is divided into a library, a main program, and an application program.
[Claim 4] The method of claim 3, wherein the library performs the conversion of the high-quality image and the motion recognition image into a motion recognition software (S / W) of a motion recognition engine using an image capture software (Software) The main program analyzes and judges whether there is an abnormality of the painting process in the motion recognition image in real time with the main S / W (Software), and the application program stores the output and the analysis history And a screen capture are performed.
The smart monitoring system according to claim 4, wherein the main program determines whether or not the abnormality is caused by a spray pattern, a conveyor surging, and a door opening generated in the coating process.
The smart monitoring system according to claim 5, wherein the spray pattern is the presence or absence of coating liquid discharge and the discharge pattern width.

The smart monitoring system according to claim 5, wherein the conveyor surging is a position of an object to be coated to be applied to the coating process.
The smart monitoring system according to claim 5, wherein the door opening is a door open angle of the painting booth in which the painting process is performed.
The smart monitoring system of claim 1, wherein the imaging module comprises two first and second cameras.
The smart monitoring system according to claim 9, wherein each of the first and second cameras is an explosion-proof camera.
The image processing apparatus according to claim 1, wherein the image processing module comprises: an image processor for receiving the image data from the image capturing module and transmitting the image data to the computer; And an image analyzer for transmitting / receiving the abnormal presence / absence image to / from the computer.
The smart monitoring system of claim 1, wherein the video output module includes a screen reproduction monitor and a portable mobile phone.
The smart monitoring system of claim 1, wherein the wireless communication device forms a WiFi wireless network.
An image capturing module for capturing a painting process in real time as image data, an image processing module for receiving the image data, an image processing unit for converting the image data into a high-quality image, A computer equipped with an artificial intelligence software to be generated, a smart monitoring system comprising a video output module for receiving and reproducing the high-definition video and the process status display video, respectively;
A painting booth in which the first and second painting robots for painting the painted body conveyed by the conveyor are installed, and the imaging module is installed inside;
A wireless network for transmitting and receiving the smart monitoring system;
Wherein the coating system comprises:
15. The coating system according to claim 14, wherein the painting booth is a painting upper booth on which an inner plate of the painting body is painted.
15. The coating system according to claim 14, wherein the wireless network limits wireless communication of the smart monitoring system to an installation space of the painting booth.

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