RU2637914C1 - Method for applying paint-lacquer coating - Google Patents

Abstract

FIELD: technological processes.

SUBSTANCE: invention relates to methods for applying a liquid paint-lacquer material (PLM) to the surface of a sheet substrate by moving rollers of a roller colouring machine of a colouring line over its surface and can be used to automatically control the process of applying a polymer PLM to a metal strip. The method for applying a paint-lacquer coating using an automatic roller colouring line comprises setting the required thickness of the dry coating layer, analyzing the initial parameters of the PLM, determining the required thickness of the wet coating layer, and adjusting the operating mode of the roller colouring machine of the colouring line, followed by applying and drying the paint-lacquer coating, continuous measurement of thicknesses of the wet and dry coating layers during the colouring process, analyzing the correctness of the colouring line settings and, if necessary, their changing. The recipe database is created, used and periodically updated to adjust the roller colouring machine of the colouring line. These recipes establish correspondence between the initial parameters of the PLM and operating parameters of the roller colouring machine of the colouring line, ensuring the formation of a necessary thickness of the wet coating layer. During analysis of the initial parameters of the PLM, a test substrate is preliminary coloured, the thickness ratio of the wet and dry coating layers is measured and the obtained ratio value is used as one of the initial parameters of the PLM for the specified recipe database.

EFFECT: invention allows to simplify the production of a coating with specified parameters and minimize the deviation of the actual thickness of the dry coating layer from the required one.

7 cl, 2 dwg

Description

The invention relates to methods for applying a liquid paint material (LKM) on the surface of a sheet substrate by moving it between the rollers of a roller dyeing machine of a paint line and can be used to automatically control the process of applying a polymer LKM to a metal strip.

The prior art method for applying a paint coating using an automatic roller painting line, including setting the required thickness of the dry coating layer, analyzing the initial parameters of the paint material, determining the required thickness of the wet coating layer and setting the operating mode of the roll painting machine of the painting line with subsequent application and drying paint and varnish coating, continuous measurement of the thickness of wet and dry coating layers during the painting process, analysis of the correctness of constructions coating line and, if necessary, modification (see. JPH patent 10249262, Cl. B05D 1/28, publ. 22.09.1998). The disadvantages of this method are the excessive complexity and relatively low accuracy of reproduction of the required thickness of the dry coating layer.

The objective of the invention is to remedy these disadvantages. The technical result consists in simplifying the production of a coating with specified parameters while minimizing the deviation of the real thickness of the dry coating layer from the required. The problem is solved, and the technical result is achieved by the fact that in the method of applying a paint coating using an automatic roller painting line, which includes setting the required thickness of the dry coating layer, analyzing the initial parameters of the paint material, determining the required thickness of the wet coating layer and setting the operating mode of the roller coating machines of the painting line with subsequent application and drying of the paint coating, continuous measurement of the thicknesses of wet and dry layers coating during the painting process, analysis of the correctness of the settings of the painting line and, if necessary, changing them, to set up the roller painting machine, the painting lines create, use and periodically update a database of recipes that establish the correspondence between the initial parameters of the paint and varnish material and the parameters of the roller painting machine of the line painting, providing the formation of the required thickness of the wet coating layer, while during the analysis of the initial parameters of the paint material itelno stained test substrate measured ratio of dry and wet thicknesses of the coating layers and the ratio value obtained is used as a starting material for the painting parameters specified database of recipes. The database of recipes is preferably created and used as follows: select from the database a recipe with the closest to the current parameters of the paint material; check the applicability of the recipe by detecting whether the thickness of the dry coating layer, expected when applying the recipe, is within the established tolerance relative to the required; if the recipe is applicable, adjust the roll dyeing machine line of painting in accordance with the parameters of its work from the recipe; if the recipe is not applicable, create a new recipe with the help of the operator and / or by directly calculating the operation parameters of the roller painting machine of the paint line from the required thickness of the dry coating layer and the parameters of the paint material. The recipe database is preferably updated as follows: assign a confidence rating value to each recipe; measuring the difference between the expected thickness of the dry coating layer according to the recipe and the actual measured thickness of the obtained dry coating layer; if the difference obtained is within the established tolerance, then the value of the confidence rating of the recipe is increased; if the resulting difference does not fit into the established tolerance, then reduce the value of the rating of the confidence of the recipe. During the application of the paint coating, its density is preferably continuously measured, and the obtained value is used in the analysis of the correctness of the settings of the roller painting machine of the painting line. During the analysis of the initial parameters of the paint material, its viscosity, density and temperature are preferably measured. In the analysis of the initial parameters of the paint material, it is preferable to take into account its type, color, manufacturer, as well as the viscosity and density declared by the manufacturer. As the operating parameters of the roller dyeing machine of the painting line, when setting it, it is preferable to use the rotational speeds of the exciting and applying rollers, the pressing force between the applying and gripping rollers, and also between the applying and supporting rollers.

In FIG. 1 is a schematic diagram of an automatic roller painting line on which the proposed method can be implemented;

in FIG. 2 - the algorithm of its operation according to the proposed method.

The proposed method of applying paintwork is designed to organize the operation of an automatic roller painting line (see Fig. 1), which includes:

1 - input device for the initial parameters of the paintwork;

2 - device for setting the required thickness of the dry coating layer;

3 - hardware-calculation complex;

4 - control unit roll painting machine;

5 - unit for measuring the dry residue of paintwork materials;

6 - unit for measuring the initial density, viscosity and temperature of the paintwork;

7 - temperature sensor applied paintwork;

8 - device for measuring the thickness of the wet coating layer;

9 - actuators of the roll dyeing machine;

10 - drying oven;

11 - a device for measuring the thickness of the dry coating layer;

12 - a bypass roller of a roller dyeing machine;

13 - an exciting roller roller painting machine;

14 - applying roller roller painting machine;

15 - supporting roller roll painting machine;

16 - metal strip;

17 - capacity with the original paintwork;

18 - pipeline;

19 - feed tray.

Simplified technological process of painting consists in transferring paintwork materials from the tank 17 to the metal strip 16 using an exciting 13 and applying 14 rollers. The roller 13 captures the paintwork materials from the tray 19. In the paintwork tray 19, the paintwork materials are supplied by a pipe 18 from the tank 17. Paintwork transfer pumps, equipment for rotating the shafts and other auxiliary equipment are not shown in the diagram for simplification. Using the support roller 15 and the bypass roller 12, the metal strip is transported. Tensioning devices for tensioning the strip are not shown in the drawings. The coated strip passes through the drying oven 10, where the evaporation of the solvent from the paintwork materials and the paintwork polymerization takes place.

During the painting of the device 8, 11, the thicknesses of the wet and dry coating layers are continuously measured by the optical method, the value of which is passed to analyze the correctness of the settings of the paint line in the hardware-calculation complex 3. To increase the accuracy of measurements, periodically wet paint on the application roller 13 is cleaned with a knife for registration of the optical signal corresponding to the reflection of the beam from its surface. Additionally, information on the speed and time of mixing of paintwork materials in the tank 19, as well as the amount of added solvent, can be received in the hardware-calculation complex 3.

The essence of the proposed method lies in the fact that to configure the roller dyeing machine create, use and periodically update the database of recipes at the disposal of the hardware-computer complex 3. These recipes are files that establish the correspondence between the initial parameters of the paintwork material and the parameters of the roller dyeing machines providing the formation of the required thickness of the wet coating layer to obtain the thickness of the dry coating layer with minimal deviation from the task Foot values. In particular, the recipe contains the necessary values of the rotation speed of the exciting 13 and 14 applying rollers, the pressing force between the applying 14 and 13 exciting rollers, as well as between the applying 14 and supporting 15 rollers. It is possible to implement the method for a three-roll application scheme, when a squeezing roller is installed between the pickup and depositing rollers, the dosing amount of paint falling from the pickup roller to the spreading roller. In this case, the recipe includes values of the rotation speeds of the exciting, squeezing and applying rollers, the pressing forces between the exciting and squeezing, squeezing and applying and between the applying and supporting rollers. The operation parameters of the roller dyeing machine from the recipe are transferred to the control unit 4 of the roller dyeing machine and then through the duplex channels with feedback through the actuators 9 act on the rollers 12-15. The parameter values are kept constant until a new command is received from control unit 4.

The first recipe is produced in the hardware and computer complex 3 based on the value of the volume dry solids, which is measured by block 5. Block 5 determines the amount of change in the volume of coatings after passing through the drying and polymerization process under conditions close to the drying and polymerization conditions in the drying oven 10. Based on of this value, you can calculate the required thickness of the wet coating layer applied to the strip 16, to obtain the desired thickness of the dry coating layer. The volumetric dry residue measurement is carried out each time when changing the tank 19, or when changing the type of paint applied.

The proposed method is implemented using a special computer program installed on the hardware-computer complex 3, as follows (see Fig. 2).

1) To determine the initial parameters of the paintwork, using block 6, measure its viscosity, density and temperature and transfer their values to the hardware-computer complex 3. On the painting line, paint a test substrate (metal strip) and measure the thickness of the wet and using the devices 8, 11 dry coating layers. Using device 1 (keyboard, touch screen), the operator enters the ratio of these thicknesses into the program dialog box, this value, as well as the type, color, manufacturer and the viscosity and density declared by the manufacturer.

2) Using device 2 (keyboard, touch screen), set the required thickness of the dry coating layer. Based on this thickness and the previously introduced ratio of the thicknesses of the wet and dry layers in the apparatus-calculation complex 3, by calculation, the necessary thickness of the wet coating layer is determined.

3) Constantly during the painting process using block 6 measure the density of the paintwork, transfer its value to the hardware-computer complex 3 and use this value when analyzing the correct settings of the roll dyeing machine.

4) If, since the initial parameters were determined in accordance with Clause 1, significant changes in the density of coatings have occurred, the measured ratio of the thicknesses of the wet and dry coating layers is adjusted as a function of density. The threshold of density change, after which an adjustment is required, is determined empirically and set by the operator.

5) From the database, select a recipe with the closest to the current paint and varnish parameters: the type of paint and varnish, the measured ratio of the thicknesses of the dry and wet coating layers and the density of paint and varnish (these and other paint and varnish parameters are contained in each recipe file).

6) When similar parameters are found in the database, paintwork materials are read from the corresponding recipe for the operation of the roll dyeing machine. In case there is no exact match, an algorithm for creating new recipes is provided below.

7) Check the applicability of the recipe by identifying whether the dry coating thickness expected when applying the recipe is within the tolerance set by the operator relative to the required. If yes, then the recipe is considered applicable and the operation parameters of the roller dyeing machine are transferred from it to the control unit 4.

8) Similar to that described in paragraph 3, using block 6, a constant viscosity control is performed and the measured values are transmitted to the hardware-calculation complex 3.

9) Similarly with p. 8, the temperature of the paintwork is controlled.

10) In addition, the air temperature in the paint application room is measured, which is also transferred to the hardware-calculation complex 3 for subsequent analysis.

11) If the selected recipe with the closest paintwork parameters in accordance with paragraph 7 is not applicable, the program proceeds to create a new recipe based on it.

12) Recipe is adjusted with the closest paint and varnish parameters on the basis of the measured current paint and varnish parameters (see paragraphs 3, 8, 9, 10) by directly calculating the operation parameters of the roll dyeing machine using a hardware-calculation complex 3.

13) The adjusted parameter value (new recipe) is displayed for analysis and confirmation by the operator.

14) The operator analyzes the generated new recipe, while being able to see the recipe taken as a basis, and all the current parameters of the paintwork. Having experience with the painting line, the operator can make an approximate conclusion about whether this recipe is suitable and see gross system errors, if any. After that, the operator makes the necessary corrections, in his opinion, in the new recipe or leaves it unchanged and confirms it, transferring it to the control unit 4 for further use.

15) The control unit 4 generates effects on the actuators 9 in the form of unified current signals. In particular, a signal proportional to the pressure on the application roller 13, on which, in turn, depends on the thickness of the applied wet coating layer.

16) Since the pressure of the clamp of the application roller 13 is an indirect indicator of the thickness of the applied wet coating layer, a regulator is introduced into the system that maintains the operating parameters of the roller painting machine in accordance with a certain thickness of the wet coating layer.

17) For the operation of the regulator specified in clause 16, a direct measurement of the thickness of the wet coating layer is performed using device 8. Information about this measurement is transmitted to the specified regulator (clause 16), which amends the operating parameters of the roller dyeing machine.

18) In order to achieve maximum regulation accuracy and make adjustments to recipes, each of them is assigned a confidence rating value. The confidence rating in arbitrary units (points) is recorded in the database as a characteristic of the recipe. To determine the confidence rating, the thickness of the dry coating layer is measured using the device 11 without stopping the painting process directly during the movement of the metal strip 16. The measurement results are transferred to the hardware-calculation complex 3.

19) After the data on the next measurement of the thickness of the dry coating layer are received, the hardware-calculation complex 3 calculates the difference between the expected value and the real value of this thickness according to the recipe.

20) Comparison of the obtained difference between the expected and real values of the thickness of the dry coating layer with the established tolerance specified by the operator.

21) If the obtained value of the difference fits into the established tolerance, then further actions depend on how the corresponding recipe was received.

22) If the obtained value of the difference fits into the tolerance, and the recipe is not taken directly from the database, but is obtained as a result of creating a new recipe in accordance with clause 12-4, then this recipe is stored in the database.

23) If the obtained difference value fits into the tolerance, and the recipe was taken from the database, the system increases its confidence rating value.

24) The value of the difference between the expected and real thicknesses of the dry coating layer (p. 19) is used to instantly adjust the parameters of the roll dyeing machine. This adjustment has a higher priority compared to the task entered by the system and the operator based on the recipe from the database, and compared to the adjustment for the wet coating layer.

25) In the case when the difference value is outside the established tolerance (p. 20), an appropriate message is generated so that the operator can take corrective actions.

26) After receiving a message about going beyond the established tolerance (p. 25), the operator checks the serviceability of measuring instruments 5-8, 11.

27) After checking the equipment, the operator enters into the hardware and computer complex 3 information on whether the devices were in good condition at the time of measuring the initial parameters of the paintwork used to select the recipe.

28) As in paragraph 21, further actions depend on whether a ready-made recipe from the database or a new recipe created taking into account corrections depending on measurements of the paintwork parameters was used.

29) If the equipment is in good condition and a new recipe has been used, then it is saved with the mark “not correct” for subsequent analysis.

30) After that, a message is generated stating that the wrong recipe was created. A message about the fact of the wrong recipe and all the necessary data for analysis (initial parameters of paintwork, etc.) are displayed on the screen.

31) If in paragraph 26 it was established that the equipment was not working properly at the time of the formation of the recipe or at the time of applying paintwork, then with the ready-made recipe from the base, no action is taken and the new recipe is not saved, since there is no confirmation of its correctness.

32) If the difference obtained does not fit into the established tolerance (paragraph 20), the equipment was in good condition, and the recipe was taken from the base, then its confidence rating is reduced.

The control frequency and the allowable fluctuation intervals of the parameter values when setting the painting line are chosen so as to avoid overshoot due to statistical fluctuations of the measured parameters.

The result of the above steps is the accumulation of correct recipes in the database, which allows minimizing the deviation of the real thickness of the dry coating layer from the required one, increasing the stability of the coating thickness and the quality of the painting line as a whole. At the same time, the use of a ready-made database greatly simplifies obtaining coverage with the specified parameters and speeds up the process of setting the painting line.

Claims (15)

1. A method of applying a paint coating using an automatic roller coating line, including setting the required thickness of the dry coating layer, analyzing the initial parameters of the paint material, determining the required thickness of the wet coating layer and setting the operating mode of the roll coating machine of the paint line with subsequent application and drying of the paint coating continuous measurement of wet and dry coating thicknesses during the painting process, analysis of the correctness of the paint line settings and, if necessary, their change, characterized in that for setting up the roller painting machine, the paint lines create, use and periodically update a database of recipes that establish the correspondence between the initial parameters of the paint and varnish material and the operating parameters of the roller painting machine of the paint line, ensuring the formation of the required thickness of the wet coating layer while in the course of analysis of the initial parameters of the paint material, the test substrate is pre-painted, measured accordingly the thickness of the wet and dry layers of the coating and use the obtained value of the ratio as one of the initial parameters of the paint material for the specified database of recipes. 2. The method according to p. 1, characterized in that the database of recipes is created and used as follows: - choose a recipe from the database with the closest to the current parameters of the paint material; - check the applicability of the recipe by identifying whether the thickness of the dry coating layer, expected when applying the recipe, is within the established tolerance relative to the required; - if the recipe is applicable, adjust the roll dyeing machine line of painting in accordance with the parameters of its work from the recipe; - if the recipe is not applicable, create a new recipe with the help of the operator and / or by directly calculating the operation parameters of the roller painting machine of the painting line from the required thickness of the dry coating layer and parameters of the paint material. 3. The method according to p. 1, characterized in that the database of recipes is updated as follows: - assign to each recipe a confidence rating value; - measure the difference between the expected thickness of the dry coating layer according to the recipe and the actual measured thickness of the obtained dry coating layer; - if the resulting difference fits into the established tolerance, then increase the value of the rating of the confidence of the recipe; - if the difference obtained does not fit into the established tolerance, then reduce the value of the rating of the confidence of the recipe. 4. The method according to p. 1, characterized in that during the application of the paint coating its density is continuously measured, and the obtained value is used in the analysis of the correctness of the settings of the roller painting machine of the painting line. 5. The method according to p. 1, characterized in that during the analysis of the initial parameters of the paint material, its viscosity, density and temperature are measured. 6. The method according to p. 1, characterized in that during the analysis of the initial parameters of the paint material take into account its type, color, manufacturing plant, as well as the viscosity and density declared by the manufacturer. 7. The method according to p. 1, characterized in that as the operation parameters of the roller dyeing machine of the painting line when setting it, the rotation speeds of the exciting and applying rollers, the compressive force between the applying and exciting rollers, as well as between the applying and supporting rollers are used.

Images