Automatic spraying methods and automatic spraying systems
Patent Information
- Application Number
- TW114112768
- Authority / Receiving Office
- TW · TW
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-04-02
- Publication Date
- 2026-10-16
- Estimated Expiration
- 2045-04-01
AI Technical Summary
Traditional spraying methods are labor-intensive, prone to human error, and inefficient, leading to inconsistent quality and increased health risks due to manual adjustment and exposure to volatile organic compounds.
An automatic spraying system and method using a computing module to simulate and analyze spraying images, adjust spray valve height and angle automatically based on image analysis, and ensure consistent quality.
Improves spraying accuracy and efficiency by reducing human intervention, ensuring consistent quality, and enhancing operational safety.
Smart Images
Figure TWG2TA001080001_001 
Figure TWG2TA001080001_002 
Figure TWG2TA001080001_003
Abstract
Description
[Technical Field]
[0001] This invention relates to spraying technology; in particular, it refers to an automatic spraying method and an automatic spraying system. [Previous Technology]
[0002] Traditional spraying methods rely on manual sampling of sprayed 3D objects to determine whether the spraying effect meets the standards, and manually adjust the height and angle of the spray valve based on the inspection results. However, manual inspection and adjustment are not only time-consuming and labor-intensive, but also require a large investment of human resources, leading to increased production costs.
[0003] Since the adjustment of the spray valve height and angle mainly relies on the operator's experience, the manual method is prone to high human error and makes it difficult to ensure stable consistency. When the spraying requirements involve high precision tolerances, traditional methods are even more difficult to maintain uniform spraying quality. In addition, the manual adjustment process is cumbersome and requires constant testing and correction, which further affects production efficiency.
[0004] In addition, the working environment of traditional manual inspection and adjustment methods is full of chemicals. Operators are exposed to volatile organic compounds (VOCs) or other spray materials that may affect health for a long time, increasing occupational safety and health risks.
[0005] Therefore, the industry urgently needs a technology that can automate detection, analysis and correction to reduce human intervention, improve production efficiency and enhance the safety of the working environment. [Summary of the Invention]
[0006] In view of the above, the purpose of the present invention is to provide an automatic spraying system and an automatic spraying method to improve spraying accuracy and production efficiency, while reducing manpower requirements and operational risks.
[0007] To achieve the above objectives, the present invention provides an automatic spraying method comprising the following steps:
[0008] A data processing step, through a computing module, calculates a scaled spraying information based on an original spraying information; wherein the original spraying information includes a plurality of cross-sectional contours of a three-dimensional object and an original height corresponding to each cross-sectional contour; wherein a spray valve of a spraying module has the original height in the direction of a vertical axis of a cross-section between a spraying outlet at an original position and a horizontal line of a cross-section.
[0009] In the overlay step, the scaling spraying information is overlaid onto the second dimension information of one of the three-dimensional objects through the computing module to generate a plurality of simulated spraying images;
[0010] A spraying step, wherein the spray valve of the spraying module sprays the three-dimensional object according to the original spraying information to form a sprayed three-dimensional object;
[0011] A detection step involves capturing multiple sprayed images of the sprayed three-dimensional object through an image capturing module and transmitting them to the computing module; the computing module receives the sprayed images.
[0012] An analysis step involves generating adjustment parameter information corresponding to each of the cross-sectional profiles based on the original spraying information, the simulated spraying images, and the spraying images using the computing module; wherein the adjustment parameter information includes an adjustment height corresponding to one of the cross-sectional profiles, and the spray valve has the adjustment height in the direction of the vertical axis of the cross-section between the spraying outlet at an adjustment position and the horizontal line of the cross-section; wherein the adjustment height is different from the original height; and
[0013] A calibration step involves transmitting the adjustment parameter information to the spraying module through the computing module, controlling the movement of the spray valve through the spraying module, and spraying a subsequent three-dimensional object according to the adjustment parameter information corresponding to each of the cross-sectional contours.
[0014] This invention provides an automatic spraying system, comprising: a spraying module, an image capturing module, and a computing module; the spraying module has a spray valve facing a three-dimensional object, the spray valve being oscillating between an original position and an adjusted position; the spray valve sprays the three-dimensional object according to original spraying information, so that the three-dimensional object forms a sprayed three-dimensional object; wherein, the original spraying information includes a plurality of cross-sectional contours of the three-dimensional object and an original height corresponding to each cross-sectional contour; the image capturing module is used to capture a plurality of sprayed images of the sprayed three-dimensional object; the computing module is connected to the spraying module and the image capturing module; the computing module calculates a scaled spraying information according to the original spraying information; the computing module superimposes the scaled spraying information onto a second dimension information of the three-dimensional object to generate a plurality of simulated sprayings. The processing module receives the spraying images from the image capturing module; based on the original spraying information, the simulated spraying images, and the spraying images, the processing module generates adjustment parameter information corresponding to each of the cross-sectional contours; the processing module transmits the adjustment parameter information to the spraying module, the spraying module controls the movement of the spray valve, and sprays a subsequent three-dimensional object according to the adjustment parameter information corresponding to each of the cross-sectional contours; wherein, the spray valve of the spraying module has an original height in the direction of the vertical axis of the cross-section between a spray outlet at an original position and a horizontal line of the cross-section; the adjustment parameter information includes an adjustment height corresponding to one of the cross-sectional contours, and the spray valve has the adjustment height in the direction of the vertical axis of the cross-section between the spray outlet at an adjusted position and the horizontal line of the cross-section; wherein, the adjustment height is different from the original height.
[0015] The advantage of this invention lies in utilizing these simulated spraying images to simulate the optimized spraying effect of the scaled spraying information on the three-dimensional object, and to provide an analysis standard for subsequent steps. Furthermore, through these spraying images, the automatic spraying system obtains a complete view of the sprayed three-dimensional object, thereby improving the accuracy of subsequent analysis. Moreover, through these adjustment parameter information, the automatic spraying system can automatically adjust the height of the spray valve, further improving spraying accuracy. By controlling the spray valve to spray the subsequent three-dimensional object according to the adjustment parameter information corresponding to each cross-sectional contour, it is ensured that the spraying of the subsequent three-dimensional object meets predetermined quality standards.
Implementation Method
[0016] To more clearly illustrate the present invention, preferred embodiments are described in detail below with reference to the accompanying drawings. Please refer to Figure 1, which shows an automatic spraying system 100 according to a preferred embodiment of the present invention. The automatic spraying system 100 includes a computing module 10, a spraying module 20, and an image capturing module 30.
[0017] As shown in Figure 1, the computing module 10 is a computer with computing capabilities and is electrically connected to the spraying module 20 and the image capturing module 30. The computing module 10 is mainly used to generate a plurality of simulated spraying images, receive a plurality of spraying images from the image capturing module 30, compare the simulated spraying images with the spraying images, generate a plurality of adjustment parameter information, and finally transmit the adjustment parameter information to the spraying module 20.
[0018] As shown in Figure 1, the spraying module 20 is used to spray a three-dimensional object M according to an original spraying information, so that the three-dimensional object M forms a sprayed three-dimensional object. In addition, the spraying module 20 is also used to receive the adjustment parameter information from the computing module 10, and spray a subsequent three-dimensional object (not shown) according to the adjustment parameter information.
[0019] As shown in Figure 2, in this embodiment, the three-dimensional object M is illustrated using a shoe sole as an example, but it is not limited thereto. In this embodiment, an unpainted shoe sole is defined as the three-dimensional object M, and the three-dimensional object M is defined as a painted three-dimensional object after being painted.
[0020] As shown in Figure 2, the spraying module 20 has a spray valve 22 facing the three-dimensional object M. In this embodiment, the spraying module 20 is a robotic arm, and the spray valve 22 is mounted on the robotic arm and can move with the robotic arm to change its setting angle or position. In this way, the robotic arm can drive the spray valve 22 to perform spraying operations around the inner wall of the shoe sole.
[0021] As shown in Figure 1, the image capturing module 30 is used to capture the sprayed images of the sprayed three-dimensional object and transmit the sprayed images to the computing module 10.
[0022] The automatic spraying system 100 is used to perform the automatic spraying method of the present invention. In other embodiments, it is not excluded that other spraying systems are used to perform the automatic spraying method of the present invention. The automatic spraying method will be described together with the automatic spraying system 100 thereafter.
[0023] As shown in Figure 3, the automatic spraying method of a first embodiment of the present invention includes the following steps.
[0024] A data processing step S11.
[0025] In the data processing step S11, the calculation module 10 calculates a scaling spray information based on an original spray information.
[0026] The data processing step S11 sequentially includes the following steps: a data transmission step S111 and a data scaling step S112.
[0027] In the data transmission step S111, the original spraying information and the first dimension information of one of the three-dimensional objects M are transmitted to the computing module 10 through the spraying module 20, and the original spraying information and the first dimension information are received through the computing module 10.
[0028] In the data scaling step S112, the calculation module 10 scales the original spraying information according to the first size information to generate scaled spraying information, wherein the scaled spraying information matches the proportion of the first size information. This ensures that the scaled spraying information adapts to the first size information of the three-dimensional object M, improving analysis accuracy.
[0029] One extraction step S12.
[0030] In the acquisition step S12, the image acquisition module 30 acquires a plurality of original images of the three-dimensional object M and transmits them to the computing module 10, and then receives these original images through the computing module 10.
[0031] In this embodiment, the image capturing module 30 is disposed at a predetermined height of the three-dimensional object M, and can capture the original images of the three-dimensional object M from different angles. These original images include a plurality of side views and a top view of the three-dimensional object M. By capturing these original images, a complete perspective of the three-dimensional object M is obtained, thereby improving the accuracy of subsequent analysis.
[0032] In this embodiment, the data processing step S11 is executed first, followed by the extraction step S12. In other embodiments, the execution order of the data processing step S11 and the extraction step S12 can be interchanged or performed simultaneously.
[0033] One superposition step S13.
[0034] In the superposition step S13, the computing module 10 superimposes the scaling spraying information onto the second size information of one of the three-dimensional objects M to generate the simulated spraying images.
[0035] In this embodiment, the second size information refers to the original images. Specifically, the computing module 10 superimposes the scaled spraying information onto the original images to generate the simulated spraying images. Through these simulated spraying images, the automatic spraying system 100 can simulate the optimized spraying effect of the scaled spraying information on the three-dimensional object M and provide an analysis standard for subsequent steps.
[0036] In this embodiment, the extraction step S12 is executed first, followed by the superposition step S13. In other embodiments, the execution order of the extraction step S12 and the superposition step S13 can be interchanged or performed simultaneously.
[0037] One spraying step S14.
[0038] In the spraying step S14, the spray valve 22 of the spraying module 20 sprays the three-dimensional object M according to the original spraying information, and the paint is sprayed onto the three-dimensional object M to form the sprayed three-dimensional object.
[0039] As shown in Figures 5 and 6, the original spraying information includes a plurality of cross-sectional contours 40 of the three-dimensional object M, an original height H1 corresponding to each cross-sectional contour 40, and an original angle Ѳ1 corresponding to each cross-sectional contour 40.
[0040] As shown in Figures 5, 6, 8 and 9, the spray valve 22 can swing between an original position P1 and an adjusted position P2 corresponding to each of the cross-sectional contours 40. As shown in Figures 5 and 6, when the spray valve 22 is in the original position P1, the spray valve 22 sprays paint onto an inner wall 42 of the corresponding cross-sectional contour 40 according to the corresponding original height H1 and the original angle Ѳ1.
[0041] Further explanation is provided that, in this embodiment, the cross-sectional contours 40 are obtained based on a three-dimensional image of the three-dimensional object M. Specifically, as shown in FIG4, a top-view two-dimensional edge contour 60 is obtained based on the three-dimensional image. Next, a plurality of cross-sectional lines 62 and a major axis L3 are calculated on the top-view two-dimensional edge contour 60, wherein the cross-sectional lines 62 are perpendicular to the major axis L3 and arranged along the direction of the major axis L3. Finally, the three-dimensional image is segmented based on the cross-sectional lines 62 to obtain the cross-sectional contours 40.
[0042] To further explain, each of the cross-sectional profiles 40 has two inner walls 42, and the inner walls 42 are respectively located on both sides of each cross-sectional profile 40. In this embodiment, as shown in FIG5, one side of each cross-sectional profile 40 is used as an example.
[0043] As shown in Figure 5, the spray valve 22 of the spraying module 20 has an original height H1 between the spray outlet 24 at the original position P1 and a horizontal line L1 in the direction of a vertical axis L2. As shown in Figure 6, when the spray valve 22 is located at the original position P1, the spray valve 22 sprays the inner wall 42 with a spraying center axis 242, wherein the spraying center axis 242 and the vertical axis L2 have an original angle Ѳ1.
[0044] In this embodiment, the overlay step S13 is performed first, followed by the spraying step S14. In other embodiments, the execution order of the overlay step S13 and the spraying step S14 can be interchanged or performed simultaneously.
[0045] Detection step S15.
[0046] In the detection step, the image capturing module 30 captures the sprayed images of the sprayed three-dimensional object and transmits them to the computing module 10, and then receives the sprayed images through the computing module 10.
[0047] In this embodiment, the sprayed images include a plurality of side views and a top view of the sprayed three-dimensional object. By capturing these sprayed images, a complete perspective of the sprayed three-dimensional object is obtained, thereby improving the accuracy of subsequent analysis.
[0048] In this embodiment, the image capturing module 30 is an ultraviolet camera used to detect the distribution of paint on the sprayed three-dimensional object, thereby confirming the integrity of the spraying.
[0049] Analysis step S16.
[0050] In the analysis step S16, the calculation module 10 generates an adjustment parameter information corresponding to each of the cross-sectional contours 40 based on the original spraying information, the simulated spraying images and the spraying images.
[0051] The analysis step S16 sequentially includes the following steps: an image enhancement step S161, a quality analysis step S162 and a deviation analysis step S163.
[0052] In the image enhancement step S161, the computing module 10 performs image enhancement processing on the sprayed images to generate a plurality of enhanced images. This improves image detail and contrast, enhancing the accuracy of subsequent analysis.
[0053] In the quality analysis step S162, the calculation module 10 uses the simulated spraying images as evaluation standards to compare with the augmented images, analyzes the differences between the simulated spraying images and the augmented images, and then calculates a spraying quality information, wherein the spraying quality information is used to evaluate the spraying accuracy and uniformity in the augmented images and to provide a basis for subsequent adjustments.
[0054] Further explanation is provided that the coating quality information includes: an unpainted area corresponding to one of the cross-sectional profiles 40, an over-painted area corresponding to another cross-sectional profile 40, and a qualified area corresponding to the remaining cross-sectional profiles 40. The unpainted area indicates that the paint does not reach the standard coverage range; the over-painted area indicates that the paint coverage exceeds the standard range; and the qualified area indicates that the coating meets the standard.
[0055] In this embodiment, the number of unpainted areas is one, and the number of overpainted areas is one. In other embodiments, the number of unpainted areas may be one or more, and the number of overpainted areas may be zero; or, in other embodiments, the number of unpainted areas may be zero, and the number of overpainted areas may be one or more.
[0056] In this embodiment, the number of qualified regions is multiple. In other embodiments, the number of qualified regions may be zero or one.
[0057] The computing module 10 can identify the painting defects of the painted three-dimensional object and provide accurate painting quality information as a basis for subsequent adjustment and optimization of the painting process.
[0058] In the deviation analysis step S163, the calculation module 10 calculates the adjustment parameter information corresponding to each of the profile contours 40 based on the spraying quality information and the original spraying information.
[0059] Specifically, the adjustment parameter information includes an adjustment height H2 and an adjustment angle Ѳ2 corresponding to one of the profile contours 40, and another adjustment height H2 and another adjustment angle Ѳ2 corresponding to the other profile contour 40, as well as a plurality of maintenance parameters.
[0060] As shown in Figures 8 and 9, the unpainted area in the coating quality information corresponds to the adjustment height H2 and adjustment angle Ѳ2 of the adjustment position P2. As shown in Figures 10 and 11, the over-painted area in the coating quality information corresponds to the adjustment height H2 and adjustment angle Ѳ2 of another adjustment position P2. For each qualified area in the coating quality information, there are corresponding maintenance parameters, which means that each qualified area will continue to be painted with the original height H1 and original angle Ѳ1 of the original position P1 without any adjustment.
[0061] As shown in Figures 8 and 10, the spray valve 22 has an adjustment height H2 between the spray outlet 24 and the horizontal line L1 of the cross section in the direction of the vertical axis L2 of the cross section at each adjustment position P2, wherein each adjustment height H2 is different from each original height H1. As shown in Figures 9 and 11, the spray valve 22 has an adjustment angle Ѳ2 between the spray center axis 244 and the vertical axis L2 of the cross section at one of the adjustment positions P2, wherein each adjustment angle Ѳ2 is different from each original angle Ѳ1.
[0062] The following describes the adjustment height H2 corresponding to the unpainted area. As shown in Figure 7, in the deviation analysis step S163, the unpainted area has an unpainted frame line 50 corresponding to the inner wall 42 of the cross-sectional profile 40. The unpainted frame line 50 intersects the inner wall 42 of the cross-sectional profile 40 at two intersection points 52, and there is a straight line distance 54 between the two intersection points 52. As shown in Figure 8, if the straight line distance 54 is greater than 0 and less than or equal to a first upper limit value, the calculation module 10 defines the adjustment height H2 as the original height H1 plus a first increased height H3. If the straight line distance 54 is greater than the first upper limit value and less than or equal to a second upper limit value, the calculation module defines the adjustment height as the original height plus a second increased height (not shown); wherein the second increased height is greater than the first increased height.
[0063] In this embodiment, the first upper limit is 3 mm, the second upper limit is 6 mm, the first increase in height is 2 mm, and the second increase in height is 4 mm; in other embodiments, the above values can be adjusted as needed.
[0064] The calculation module 10 can automatically adjust the height of the spray valve 22 according to the actual deviation of the unpainted area to improve the spray coverage. By precisely controlling the adjustment height H2, the occurrence of unpainted areas can be effectively reduced, the overall spray quality can be improved, and the stability and consistency of the spraying process can be optimized.
[0065] The following describes the adjustment angle Ѳ2 corresponding to the unpainted area. As shown in Figures 7 and 9, if the straight-line distance 54 is greater than 0 and less than or equal to a third upper limit value, the calculation module 10 defines the adjustment angle Ѳ2 as the original angle Ѳ1 plus a first increase angle Ѳ3; if the straight-line distance 54 is greater than the third upper limit value and less than or equal to a fourth upper limit value, the calculation module defines the adjustment angle Ѳ2 as the original angle Ѳ1 plus a second increase angle (not shown), wherein the second increase angle is greater than the first increase angle Ѳ3.
[0066] The calculation module 10 can automatically adjust the angle of the spray valve 22 according to the actual deviation of the unpainted area to improve the spray coverage. By precisely controlling each adjustment angle Ѳ2, the occurrence of unpainted areas can be effectively reduced, the overall spray quality can be improved, and the stability and consistency of the spraying process can be optimized.
[0067] In this embodiment, the unpainted area of the coating quality information corresponds to the adjustment height H2 and the adjustment angle Ѳ2 of the adjustment position P2. That is, the calculation module 10 can automatically adjust the height and angle of the spray valve 22 simultaneously based on the unpainted area. In other embodiments, the unpainted area of the coating quality information may also correspond to the adjustment height H2 of the adjustment position P2 and the original angle Ѳ1 of the original position P1. In this case, the calculation module 10 only adjusts the height of the spray valve 22 and does not adjust the angle of the spray valve 22. In addition, in other embodiments, the unpainted area of the coating quality information may also correspond to the original height H1 of the original position P1 and the adjustment angle Ѳ2 of the adjustment position P2. That is, the calculation module 10 only adjusts the angle of the spray valve 22 and does not adjust the height of the spray valve 22. A flexible adjustment strategy ensures that, under different circumstances, whether adjusting the height or angle, precise control can be made to meet specific needs, thereby optimizing coating quality and improving coverage and uniformity.
[0068] The following describes the adjustment height H2 corresponding to the oversprayed area. As shown in Figure 10, in the deviation analysis step S163, the calculation module 10 defines the adjustment height H2 as the original height H1 minus a first reduction height H4.
[0069] The computing module 10 can automatically adjust the height of the spray valve 22 according to the oversprayed area to improve the spraying accuracy. By precisely controlling the adjustment height H2, the occurrence of the oversprayed area can be effectively reduced, the overall spraying quality can be improved, and the stability and consistency of the spraying process can be optimized.
[0070] The following describes the adjustment angle Ѳ2 corresponding to the over-sprayed area. As shown in FIG11, in the deviation analysis step S163, the calculation module 10 defines the adjustment angle Ѳ2 as the original angle Ѳ1 minus a first reduction angle Ѳ4. In this embodiment, the first reduction angle Ѳ4 is 5 degrees; in other embodiments, it is not limited to this.
[0071] The calculation module 10 can automatically adjust the angle of the spray valve 22 according to the oversprayed area to improve the spraying accuracy. By precisely controlling the adjustment angle Ѳ2, the occurrence of the oversprayed area can be effectively reduced, the overall spraying quality can be improved, and the stability and consistency of the spraying process can be optimized.
[0072] In this embodiment, the over-sprayed area of the coating quality information corresponds to the adjustment height H2 and the adjustment angle Ѳ2 of the adjustment position P2. That is, the calculation module 10 can automatically adjust the height and angle of the spray valve 22 simultaneously based on the over-sprayed area. In other embodiments, the unsprayed area of the coating quality information may also correspond to the adjustment height H2 of the adjustment position P2 and the original angle Ѳ1 of the original position P1. In this case, the calculation module 10 only adjusts the height of the spray valve 22 and does not adjust the angle of the spray valve 22. In addition, in other embodiments, the over-sprayed area of the coating quality information may also correspond to the original height H1 of the original position P1 and the adjustment angle Ѳ2 of the adjustment position P2. That is, the calculation module 10 only adjusts the angle of the spray valve 22 and does not adjust the height of the spray valve 22. A flexible adjustment strategy ensures that, under different circumstances, whether adjusting the height or angle, precise control can be made to meet specific needs, thereby optimizing coating quality and improving coverage and uniformity.
[0073] One calibration step S17.
[0074] In the correction step S17, the adjustment parameter information is transmitted to the spraying module 20 through the calculation module 10, the spraying module 20 controls the movement of the spray valve 22, and the subsequent three-dimensional object is sprayed according to the adjustment parameter information corresponding to each of the cross-sectional contours 40.
[0075] This ensures that the subsequent coating of the three-dimensional object meets the predetermined quality standards, thereby significantly improving the quality and stability of the product.
[0076] As shown in Figure 12, the automatic spraying method of a second embodiment of the present invention has steps that are substantially the same as those of the automatic spraying method of the first embodiment described above. The difference is that, in the first embodiment, the automatic spraying method includes the acquisition step S12, and in the overlay step S13, the second size information is the original images, and the computing module 10 overlays the scaled spraying information onto the original images to generate the simulated spraying images. In this embodiment, the automatic spraying method does not include the acquisition step, and in the overlay step S22, the second size information is the first size information, and the computing module 10 overlays the scaled spraying information onto the first size information to generate the simulated spraying images. In short, this embodiment omits the acquisition of the original images of the three-dimensional object M, and instead uses the existing first size information to generate the simulated spraying images.
[0077] In this second embodiment, by omitting the step of capturing the original images, the scaled spraying information is directly superimposed onto the first size information, simplifying the process and improving computational efficiency. This processing method can effectively shorten the preparation time for spraying simulation, and can also reduce the need for the image capturing module 30 in certain situations, making the entire spraying process more efficient and convenient.
[0078] In summary, the automatic spraying system 100 and automatic spraying method of the present invention utilize simulated spraying images to simulate the optimized spraying effect of the scaled spraying information on the three-dimensional object M, and provide analysis standards for subsequent steps. Furthermore, through these spraying images, the automatic spraying system 100 ensures that it obtains a complete view of the sprayed three-dimensional object, thereby improving the accuracy of subsequent analysis. Moreover, through these adjustment parameter information, the automatic spraying system 100 can automatically adjust the height and angle of the spray valve 22, further improving the spraying accuracy. By controlling the spray valve 22 to spray the subsequent three-dimensional object according to the adjustment parameter information corresponding to each cross-sectional contour 40, it is ensured that the spraying of the subsequent three-dimensional object meets predetermined quality standards.
[0079] The above description is only a preferred embodiment of the present invention. Any equivalent changes made by applying the present invention specification and the claims should be included within the patent scope of the present invention. [Simplified Explanation of the Diagram]
[0080] Figure 1 is a schematic diagram of an automatic spraying system according to a preferred embodiment of the present invention; Figure 2 is a perspective view of the automatic spraying method of the first embodiment described above, illustrating that the three-dimensional object is taken as an example of a shoe sole; Figure 3 is a flowchart of the automatic spraying method of the first embodiment of the present invention; Figure 4 is a schematic diagram of the automatic spraying method of the first embodiment described above, revealing the top-view two-dimensional edge contour; Figure 5 is a schematic diagram of the automatic spraying method of the first embodiment described above, revealing the original height corresponding to each of the cross-sectional contours; Figure 6 is a schematic diagram of the automatic spraying method of the first embodiment described above, revealing the original angle corresponding to each of the cross-sectional contours; Figure 7 is a schematic diagram of the automatic spraying method of the first embodiment described above, revealing the unsprayed frame line corresponding to one of the cross-sectional contours; Figure 8 is a schematic diagram of the automatic spraying method of the first embodiment described above, revealing the adjusted height corresponding to the unsprayed area; Figure 9 is a schematic diagram of the automatic spraying method of the first embodiment described above, revealing the adjusted angle corresponding to the unsprayed area; Figure 10 is a schematic diagram of the automatic spraying method of the first embodiment described above, revealing the adjusted height corresponding to the oversprayed area; Figure 11 is a schematic diagram of the automatic spraying method of the first embodiment described above, illustrating the adjustment angle corresponding to the oversprayed area; Figure 12 is a flowchart of the automatic spraying method of the second embodiment of the present invention.
Claims
1. An automatic spraying method, comprising the following steps: a data processing step, wherein a computing module calculates scaled spraying information based on original spraying information; wherein the original spraying information includes a plurality of cross-sectional contours of a three-dimensional object and an original height corresponding to each of the cross-sectional contours; wherein a spray valve of a spraying module has the original height in a vertical axis direction of a cross-section between a spray outlet at an original position and a horizontal line of the cross-section; a superposition step, wherein the computing module superimposes the scaled spraying information onto a second dimension of the three-dimensional object to generate a plurality of simulated spraying images; a spraying step, wherein the spray valve of the spraying module sprays the three-dimensional object according to the original spraying information to form a sprayed three-dimensional object; a detection step, wherein an image capturing module captures a plurality of sprayed images of the sprayed three-dimensional object and transmits them to the computing module; and the computing module receives the sprayed images. One analysis step involves the computational module generating adjustment parameter information corresponding to each cross-sectional profile based on the original spraying information, the simulated spraying images, and the spraying images; wherein, The adjustment parameter information includes an adjustment height corresponding to one of the profile contours, wherein the spray valve has the adjustment height in the direction of the vertical axis of the profile between the spray outlet and the horizontal line of the profile at an adjustment position; wherein the adjustment height is different from the original height; and a correction step, wherein the adjustment parameter information is transmitted to the spraying module through the computing module, the spraying module controls the movement of the spray valve, and sprays a subsequent three-dimensional object according to the adjustment parameter information corresponding to each profile contour.
2. The automatic spraying method as described in claim 1, wherein the data processing step comprises the following steps: a data transmission step, wherein the original spraying information and a first dimension information of the three-dimensional object are transmitted to the computing module through the spraying module, and the original spraying information and the first dimension information are received through the computing module; and a data scaling step, wherein the original spraying information is scaled through the computing module to generate scaled spraying information; wherein, The scaling spraying information is proportionally matched to the first size information.
3. The automatic spraying method as described in claim 1 further includes an acquisition step, which is disposed between the data processing step and the spraying step, or disposed before the data processing step; in the acquisition step, a plurality of original images of the three-dimensional object are acquired by the image acquisition module, and the original images are transmitted to the computing module; in the overlay step, the second size information is the original images.
4. The automatic spraying method as described in claim 2, wherein in the overlay step, the second dimension information is the same as the first dimension information.
5. The automatic spraying method as described in claim 1, wherein the analysis step comprises the following steps: an image enhancement step, wherein the computational module performs image enhancement processing on the spraying images to generate a plurality of enhanced images; a quality analysis step, wherein the computational module compares the simulated spraying images with the enhanced images to calculate spraying quality information; and a deviation analysis step, wherein the computational module calculates the adjustment parameter information corresponding to each of the profile contours based on the spraying quality information and the original spraying information.
6. The automatic spraying method as described in claim 5, wherein, The coating quality information includes an uncoated area corresponding to one of the cross-sectional contours; in the deviation analysis step, the uncoated area has an uncoated frame line corresponding to the inner wall of one of the cross-sectional contours, and the uncoated frame line intersects the inner wall of the cross-sectional contour at two intersection points, with a straight line distance between the two intersection points; if the straight line distance is greater than 0 and less than or equal to a first upper limit value, the calculation module defines the adjustment height as the original height plus a first increase height; if the straight line distance is greater than the first upper limit value and less than or equal to a second upper limit value, the calculation module defines the adjustment height as the original height plus a second increase height; wherein, the second increase height is greater than the first increase height.
7. The automatic spraying method as described in claim 6, wherein in the data processing step, the original spraying information includes an original angle corresponding to each of the profile contours, wherein the spray valve has the original angle between a spraying center axis at one of the original positions and a profile vertical axis; in the deviation analysis step, the adjustment parameter information includes an adjustment angle corresponding to one of the profile contours, wherein the spray valve has the adjustment angle between a spraying center axis at one of the adjustment positions and the profile vertical axis; if the straight-line distance is greater than 0 and less than or equal to a third upper limit value, the calculation module defines the adjustment angle as the original angle plus a first increase angle; if the straight-line distance is greater than the third upper limit value and less than or equal to a fourth upper limit value, the calculation module defines the adjustment angle as the original angle plus a second increase angle; wherein... The second increase angle is greater than the first increase angle.
8. The automatic spraying method as described in claim 5, wherein, The coating quality information includes an over-coated area corresponding to one of the profile contours; in the deviation analysis step, the calculation module defines the adjustment height as the original height minus a first reduction height.
9. The automatic spraying method as described in claim 8, wherein in the data processing step, the original spraying information includes an original angle corresponding to each of the profile contours, wherein the spray valve has the original angle between a spray center axis and a profile vertical axis at one of the original positions; in the deviation analysis step, the adjustment parameter information includes an adjustment angle corresponding to one of the profile contours, wherein the spray valve has the adjustment angle between a spray center axis and a profile vertical axis at one of the adjustment positions; the calculation module defines the adjustment angle as the original angle minus a first reduction angle.
10. An automatic spraying system, comprising: a spraying module having a spray valve facing a three-dimensional object, the spray valve being oscillating between an initial position and an adjusted position; the spray valve spraying the three-dimensional object according to initial spraying information, thereby forming a sprayed three-dimensional object; wherein, The original spraying information includes a plurality of cross-sectional contours of the 3D object and an original height corresponding to each cross-sectional contour; an image capturing module for capturing a plurality of sprayed images of the sprayed 3D object; and a calculation module connected to the spraying module and the image capturing module; the calculation module calculates a scaled spraying information based on the original spraying information; the calculation module superimposes the scaled spraying information onto a second dimension of the 3D object to generate a plurality of simulated spraying images; the calculation module receives the spraying images from the image capturing module; the calculation module generates an adjustment parameter information corresponding to each cross-sectional contour based on the original spraying information, the simulated spraying images, and the spraying images; the calculation module transmits the adjustment parameter information to the spraying module, the spraying module controls the movement of the spray valve, and sprays a subsequent 3D object according to the adjustment parameter information corresponding to each cross-sectional contour; The spray valve of the spraying module has an original height in the direction of the vertical axis of the cross-section between a spray outlet in an original position and a horizontal line of the cross-section; the adjustment parameter information includes an adjustment height corresponding to one of the cross-sectional profiles, and the spray valve has an adjustment height in the direction of the vertical axis of the cross-section between the spray outlet in an adjusted position and the horizontal line of the cross-section; wherein the adjustment height is different from the original height.
11. The automatic spraying system as described in claim 10, wherein, The spraying module transmits the original spraying information and the first dimension information of one of the three-dimensional objects to the computing module. The computing module receives the original spraying information and the first dimension information. The computing module scales the original spraying information to generate scaled spraying information. The scaled spraying information is proportionally matched with the first dimension information.
12. The automatic spraying system as described in claim 10, wherein, The image capturing module is used to capture multiple original images of the three-dimensional object and transmit these original images to the computing module; wherein, the second size information is these original images.
13. The automatic spraying system as described in claim 11, wherein, The second dimension information is the same as the first dimension information.
14. The automatic spraying system as described in claim 10, wherein, The computing module performs image intensification processing on the spraying images to generate multiple intensified images; the computing module compares the simulated spraying images with the intensified images to calculate spraying quality information; the computing module calculates the adjustment parameter information for each profile based on the spraying quality information and the original spraying information.
15. The automatic spraying system as described in claim 14, wherein, The coating quality information includes an uncoated area corresponding to one of the cross-sectional contours. The uncoated area has an uncoated frame line on the inner wall of one of the cross-sectional contours. The uncoated frame line intersects the inner wall of the cross-sectional contour at two intersection points, and there is a straight line distance between the two intersection points. If the straight line distance is greater than 0 and less than or equal to a first upper limit value, the calculation module defines the adjustment height as the original height plus a first increase height. If the straight line distance is greater than the first upper limit value and less than or equal to a second upper limit value, the calculation module defines the adjustment height as the original height plus a second increase height. Wherein, the second increase height is greater than the first increase height.
16. The automatic spraying system as described in claim 15, wherein the original spraying information includes an original angle corresponding to each of the profile contours, wherein the spray valve has the original angle between a spray center axis and a profile vertical axis at one of the original positions; the adjustment parameter information includes an adjustment angle corresponding to one of the profile contours, wherein the spray valve has the adjustment angle between a spray center axis and the profile vertical axis at one of the adjustment positions; if the straight-line distance is greater than 0 and less than or equal to a third upper limit value, the calculation module defines the adjustment angle as the original angle plus a first increase angle; if the straight-line distance is greater than the third upper limit value and less than or equal to a fourth upper limit value, the calculation module defines the adjustment angle as the original angle plus a second increase angle; wherein, The second increase angle is greater than the first increase angle.
17. The automatic spraying system as described in claim 14, wherein, The coating quality information includes an over-coated area corresponding to one of the profile contours; the calculation module defines the adjusted height as the original height minus a first reduction height.
18. The automatic spraying system as described in claim 17, wherein, The original spraying information includes an original angle corresponding to each of the profile contours, wherein the spray valve has the original angle between the spray center axis of one of the original positions and a vertical axis of the profile; the adjustment parameter information includes an adjustment angle corresponding to one of the profile contours, wherein the spray valve has the adjustment angle between the spray center axis of one of the adjustment positions and the vertical axis of the profile; the calculation module defines the adjustment angle as the original angle minus a first reduction angle.