Method, device and system for automatic color painting of ceramic tiles

Abstract

The present invention discloses a method, device and system for automatic coloring of ceramic tiles. The method detects ceramic tiles to obtain a first optical image of the ceramic tiles, queries a pre-established standard ceramic tile database based on the first optical image, and obtains the position coordinates and color number values ​​of the detected ceramic tiles with color difference defects; provides an encoder to capture the pulse signal of the production line where the detected ceramic tiles are located, and calculates in combination with the rotation ratio of the production line and the diameter of the rotating wheel to obtain the transmission speed of the detected ceramic tiles on the production line; substitutes the position coordinates and transmission speed data into a formula T=Y / V to obtain a delay control signal; drives a brush module to classify and color-mark the parts of the detected ceramic tiles with color difference defects based on the delay control signal and the color number value, and applies the automatic coloring method for ceramic tiles to an automatic coloring device for ceramic tiles, so that machines can replace manual coloring, liberate labor, avoid wrong coloring and missing coloring, and improve production efficiency.

Description

Technical Field

[0001] The invention relates to the field of ceramic tile production, and in particular to a ceramic tile automatic color painting method, device and system. Background Art

[0002] During the production process of ceramic tiles, due to kiln temperature, inkjet process, etc., there will be color deviation problems on the surface of ceramic tiles. At present, the process of ceramic tile color separation in the market has always been solved by manual color drawing, which has slow color separation efficiency. When used in scenes with fast production speed of assembly line, workers are prone to wrong drawing or missing drawing due to visual fatigue caused by long-term high-intensity work and the influence of subjective feelings. Summary of the invention

[0003] Based on this, it is necessary to provide an automatic, low-cost, and high-efficiency method, device, and system for automatic tile color painting in order to address the problems in the above-mentioned existing tile color separation process, which has low operating efficiency, is prone to mis-painting and omissions, and cannot adapt to faster tile production lines.

[0004] In a first aspect, the present application provides a method for automatically painting a tile, comprising the following steps:

[0005] Detecting the ceramic tile, obtaining a first optical image of the ceramic tile, and querying a pre-established standard ceramic tile database based on the first optical image to obtain the position coordinates and color number values ​​of the detected ceramic tile having color difference defects;

[0006] Obtain the transmission speed of the inspected tiles on the production line;

[0007] Performing data calculation according to the position coordinates and the transmission speed to obtain a delay control signal;

[0008] The brush module is driven according to the delay control signal and the color number value to classify and mark the detected tiles with colors.

[0009] In one embodiment, the specific steps of inspecting the tile, acquiring a first optical image of the tile, and querying a pre-established standard tile database based on the first optical image to obtain the position coordinates and color number values ​​of the inspected tile having a color difference defect include:

[0010] Taking a first optical image of the inspected tile, using two adjacent sides of the first optical image as an X-axis and a Y-axis respectively, and establishing a first rectangular coordinate system based on the first optical image;

[0011] According to the first optical image, a pre-established standard tile database is queried to obtain a standard tile image corresponding to the color number of the inspected tile. The first optical image and the standard tile image are compared to obtain the position coordinates of the color difference defect of the inspected tile in the first rectangular coordinate system and its color number value.

[0012] In one embodiment, the specific steps of obtaining the transmission speed of the inspected tile on the production line include:

[0013] An encoder is provided, which captures the pulse signal of the production line where the inspected tiles are located, and calculates the transmission speed of the inspected tiles on the production line in combination with the rotation ratio and the diameter of the rotating wheel of the production line to obtain the transmission speed of the inspected tiles on the production line.

[0014] In one embodiment, the specific steps of performing data calculation to obtain the delay control signal according to the position coordinates and the transmission speed include:

[0015] Substitute the position coordinates and transmission speed into the formula for calculation, where Y is the Y-axis value of the position coordinate, V is the transmission speed of the inspected tile on the production line, and T is the delay control signal.

[0016] In one embodiment, the steps of driving the brush module according to the delay control signal and the color number value to classify and mark the detected tiles are as follows:

[0017] The timing starts when the detected tile enters the preset designated position, and after the delay time corresponding to the delay control signal, the brush module is triggered to start;

[0018] According to the color number value, the brush module classifies and marks the locations where the color difference defects of the detected tiles exist;

[0019] The brush module is reset. After the brush module completes the last classification and color identification, the brush module automatically returns to its initial state.

[0020] In one embodiment, there are multiple color number values, each of which is assigned a unique classification color symbol, and the classification color symbol is used to distinguish color difference levels.

[0021] In one embodiment, before the step of performing data calculation to obtain the delay control signal according to the position coordinates and the transmission speed, the step further includes:

[0022] Determining the validity of a data packet consisting of the position coordinates, the color number value, and the transmission speed;

[0023] If the sum of all bytes of the data packet is equal to zero, it is determined to be valid, and a first signal is generated to start the data calculation process according to the first signal.

[0024] The present invention also provides a device for automatically painting tiles, comprising:

[0025] The tile color detection unit detects the tile, obtains a first optical image of the tile, and queries a pre-established standard tile database based on the first optical image to obtain the position coordinates and color number values ​​of the detected tile where the color difference defect exists;

[0026] A first controller, the first controller is electrically connected to the tile color detection unit, and the first controller is used to obtain the transmission speed of the detected tile on the production line;

[0027] a second controller, the second controller being electrically connected to the first controller, and the second controller being used to perform data calculation according to the position coordinates and the transmission speed to obtain a delay control signal;

[0028] A tile coloring unit is electrically connected to the second controller and is used to classify and color-mark the detected tiles according to the delay control signal and the color number value.

[0029] In one embodiment, the tile color detection unit communicates with the first controller using a CAN bus.

[0030] In one embodiment, the first controller and the second controller use RS485 bus communication. By using RS8485 bus communication mode between the first controller and the second controller, RS485 can communicate over long distances, and the structure is simple and reliable. The second controller can be deployed over long distances relative to the first controller, so that the management personnel can remotely manage and control the tile painting process.

[0031] The present invention also provides a tile automatic coloring system, comprising: a memory and a processor, wherein the memory is used to store a tile automatic coloring program, and the processor runs the tile automatic coloring program to enable the tile automatic coloring system to execute the above-mentioned tile automatic coloring method.

[0032] One of the above technical solutions has the following advantages and beneficial effects:

[0033] In the above-mentioned method for automatic coloring of tiles, by acquiring a first optical image of the tile, and based on the first optical image, querying a pre-established standard tile database, the position coordinates and color number values ​​of the detected tiles with color defects are obtained; by providing an encoder to capture the pulse signal of the production line where the detected tiles are located, the transmission speed of the detected tiles on the production line is obtained by combining the rotation ratio of the production line and the diameter of the rotating wheel; by substituting the position coordinates and transmission speed data into the formula T=Y / V, a delay control signal is obtained; and by driving the brush module according to the delay control signal and the color number value, the parts of the detected tiles with color defects are classified and marked with colors. The automatic tile coloring device of the present application comprises a tile color detection unit which takes a picture of the tiles on the production line to obtain a first optical image of the detected tiles, queries a pre-established standard tile database based on the first optical image, obtains a corresponding standard tile image, identifies the color difference defect position and the color number value of the detected tiles, establishes a first rectangular coordinate system with two sides connected by the first optical image as the X-axis and the Y-axis, and reads the position coordinates of the current color difference defect position in the first rectangular coordinate system; a first controller is connected to an encoder, receives the transmission speed of the detected tiles on the production line measured by the encoder, and receives the position coordinates and the color number value sent by the tile color detection unit; a second controller receives the position coordinates, the transmission speed and the color number value sent by the first controller, substitutes the position coordinates and the transmission speed into the formula T=Y / V, and obtains a delay control signal; and drives the tile coloring unit to classify and color-mark the detected tiles based on the delay control signal and the color difference value, wherein the machine replaces manual coloring throughout the process, liberating labor, while avoiding wrong coloring and missing coloring, and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic diagram of the first process of the method for automatically painting the color of tiles;

[0035] Figure 2 A second flow chart of the method for automatically painting ceramic tiles;

[0036] Figure 3 The third process diagram of the method for automatically painting the color of ceramic tiles is shown;

[0037] Figure 4 It is a schematic diagram of the process of the automatic tile painting device. DETAILED DESCRIPTION

[0038] In order to more clearly understand the above-mentioned purpose, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0039] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0040] Example 1

[0041] The first embodiment of the present application discloses a method for automatically painting tiles, such as Figure 1 As shown, a method for automatically painting the color of a tile comprises the following steps:

[0042] Step S100, inspecting the ceramic tile, obtaining a first optical image of the inspected ceramic tile, and querying a pre-established standard ceramic tile database based on the first optical image to obtain the position coordinates of the color difference defect of the inspected ceramic tile and its color number value;

[0043] Step S200, obtaining the transmission speed of the inspected tile on the production line;

[0044] Step S300, performing data calculation to obtain a delay control signal according to the position coordinates and the transmission speed;

[0045] Step S400, driving the brush module according to the delay control signal and the color number value to classify and color-mark the detected tiles.

[0046] It should be noted that, for tiles with different color differences, their corresponding first optical images are also different.

[0047] like Figure 2 As shown, in addition to the features of the above embodiments, this embodiment further defines that: in step S100, the ceramic tile is detected, a first optical image of the detected ceramic tile is obtained, and a pre-established standard ceramic tile database is queried according to the first optical image to obtain the position coordinates of the detected ceramic tile having a color difference defect and its color number value. The specific steps include:

[0048] Step S110, taking a first optical image of the inspected tile, using two adjacent sides of the first optical image as an X-axis and a Y-axis respectively, and establishing a first rectangular coordinate system based on the first optical image;

[0049] Specifically, when the inspected tile enters the designated area on the production line and triggers the photosensor, the tile color detection unit 10 takes a picture of the inspected tile to obtain a first optical image, and establishes a first rectangular coordinate system based on the first optical image with the two adjacent sides of the first optical image as the X-axis and the Y-axis.

[0050] Optionally, in step S110, a first optical image of the inspected tile is captured, and a polar coordinate system is established based on the first optical image;

[0051] Step S120, based on the first optical image, query a pre-established standard tile database to obtain a standard tile image corresponding to the color number of the tile being tested, and compare the first optical image with the standard tile image to obtain the position coordinates of the color difference defect of the tile being tested in the first rectangular coordinate system and its color number value.

[0052] The standard tile database is pre-established by the system, and the standard tile database may include a number of standard tile images. For example, standard tiles corresponding to various colors are manually defined, and optical images of standard tiles are captured and entered into the standard tile database. It should be noted that if the optical image corresponding to the detected tile cannot match the optical image of the corresponding standard tile in the standard tile database, the current detected tile can be manually defined as the standard tile of the color.

[0053] Specifically, the inspected tile enters the designated area and triggers the photosensitive sensor, and the tile color detection unit 10 takes a picture of the inspected tile to obtain a first optical image, and establishes a first rectangular coordinate system based on the first optical image with the two adjacent sides of the first optical image being the X-axis and the Y-axis respectively. At the same time, the standard tile database is queried according to the first optical image to obtain a standard tile image corresponding to the first optical image, and after comparative analysis, the position where the inspected tile has a color difference defect is obtained, and the position coordinates of the color difference defect in the first rectangular coordinate system are read out; the tile color detection unit 10 includes a color number determination module, which calculates the color difference value between the first optical image and its corresponding standard tile image through the color number determination module, and determines the color number value of the inspected tile with a color difference defect.

[0054] In addition to the features of the above embodiments, this embodiment further defines that: in step S200, the specific steps of obtaining the transmission speed of the detected tile on the production line include:

[0055] An encoder 30 is provided, which captures the pulse signal of the production line where the inspected tiles are located, and calculates the transmission speed of the inspected tiles on the production line in combination with the rotation ratio and the diameter of the rotating wheel of the production line to obtain the transmission speed of the inspected tiles on the production line.

[0056] Specifically, the first controller 20 is electrically connected to the encoder 30. The encoder 30 captures the pulse signal of the production line where the inspected tiles are located, and calculates the transmission speed of the inspected tiles on the production line based on the rotation ratio and the diameter of the rotating wheel of the production line. The encoder 30 then transmits the transmission speed to the first controller 20.

[0057] In addition to the features of the above embodiment, this embodiment further defines that: in step S300, the specific steps of performing data calculation to obtain the delay control signal according to the position coordinates and the transmission speed include:

[0058] Substitute the position coordinates and transmission speed into the formula T=Y / V for calculation, where Y is the Y-axis value of the position coordinate, V is the transmission speed of the inspected tile on the production line, and T is the delay control signal.

[0059] Specifically, the second controller 40 receives the transmission speed sent by the encoder 30 and the position coordinates sent by the tile color detection unit 10, and completes the calculation of the delay control signal in the processor, that is, substituting the Y-axis value and the transmission speed in the position coordinates into the formula T=Y / V for calculation, thereby obtaining the delay control signal.

[0060] like Figure 3 As shown, in addition to the features of the above embodiment, this embodiment further defines: in step S400, the specific steps of classifying and marking the detected tiles according to the delay control signal and the color number value are as follows:

[0061] Step S410, the timing starts after the detected tile enters the preset designated position, and after the delay time corresponding to the delay control signal, the brush module is triggered to start;

[0062] Specifically, after the inspected tile enters the preset designated position, the timing timer in the second controller 40 starts timing. After the delay time corresponding to the delay control signal, the second controller 40 sends a driving signal to the tile painting unit 50 through the output port. The tile painting unit 50 includes a brush module, a servo motor, and a turntable. After receiving the driving signal, the servo motor drives the turntable to rotate. The brush module is on the turntable, and the rotation of the turntable drives the brush module to rotate, thereby marking the position where the color difference defect of the inspected tile exists.

[0063] Step S420: According to the color number value, the brush module classifies and marks the locations where the detected tiles have color difference defects.

[0064] Specifically, each color number value is converted into the number of pulses received by the servo motor. For example, color number one is 1000 pulses, color number two is 2000 pulses, and 1000 pulses realize one rotation of the turntable. The conversion between the color number value and the pulse number is completed in the processor. According to different color number values, the servo motor rotates differently, so that the number of rotations of the turntable is different, resulting in different color painting effects of the brush module on the tiles, thereby achieving the purpose of distinguishing color levels;

[0065] Step S430, the brush module is reset. After the brush module completes the last classification and color identification, the brush module automatically returns to the initial state;

[0066] Specifically, after the brush module completes the classification and color marking of the currently inspected tile, the motor driving the brush module is automatically reset, and the instruction driving the brush module is also cleared, waiting for the next inspected tile to be classified and marked; before classifying and color marking each tile, the brush module is reset to avoid the situation where the initial position of the brush module in the color marking is inconsistent with the initial position of the inspected tile with color difference defects, resulting in the position of the mark being inconsistent with the position of the color difference defect of the inspected tile.

[0067] In addition to the features of the above-mentioned embodiment, the present embodiment further defines that: there are multiple color number values, each color number value is assigned a unique classification color symbol, and the classification color symbol is used to distinguish the color difference level.

[0068] In addition to the features of the above embodiment, this embodiment further defines that: in step S300, the step of performing data calculation to obtain a delay control signal according to the position coordinates and the transmission speed also includes:

[0069] Determine the validity of a data packet consisting of location coordinates, color number values, and transmission speed;

[0070] If the sum of all bytes of the data packet is equal to zero, it is determined to be valid, and a first signal is generated to start the process of calculating the delay control signal according to the first signal.

[0071] Specifically, before obtaining the delay control signal, the second controller 40 verifies the data sent by the first controller 20, such as adding a check code to the data of the transmission speed and color number value to form a data packet, and adding all the bytes of the data packet in the processor. If the result of adding all the bytes is equal to zero, the data packet is determined to be valid, and the processor calculates the delay control signal. Otherwise, the processor stops calculating the delay control signal, resulting in the second controller 40 not driving the tile coloring unit 50 to classify and color the detected tiles. By increasing the verification of the validity of the data packet, data errors that occur during the transmission process can be avoided, thereby effectively improving the reliability of the automatic tile coloring method.

[0072] Optionally, the verification of the validity of the data packet is not limited to the above-mentioned cumulative check method, but can also be a parity check, a CRC check, etc.

[0073] In summary, the automatic coloring method for tiles provided by the present invention obtains the first optical image of the inspected tile, and queries a pre-established standard tile database based on the first optical image to obtain the position coordinates and color number values ​​of the inspected tile with color difference defects; provides an encoder 30 to capture the pulse signal of the production line where the inspected tile is located, and calculates the transmission speed of the inspected tile on the production line in combination with the rotation ratio of the production line and the diameter of the rotating wheel; obtains the delay control signal by substituting the position coordinates and transmission speed data into the T=Y / V formula; and drives the brush module to classify and color-mark the parts of the inspected tile with color difference defects through the delay control signal and the color number value, thereby replacing traditional manual coloring, liberating labor, improving production efficiency, and increasing economic benefits.

[0074] Example 2

[0075] The second embodiment of the present invention provides a laser positioning control device for ceramic tile defects, including: a ceramic tile color detection unit 10, the ceramic tile color detection unit 10 is used to obtain a first optical image of the ceramic tile to be detected, and according to the first optical image, query a pre-established standard ceramic tile database to obtain the position coordinates and color number values ​​of the color difference defects corresponding to the first optical image; a first controller 20, the first controller 20 is electrically connected to the ceramic tile color detection unit 10, and the first controller 20 is used to obtain the transmission speed of the ceramic tile to be detected on the production line; a second controller 40, the second controller 40 is electrically connected to the first controller 20, and the second controller 40 is used to perform data calculation according to the position coordinates and the transmission speed to obtain a delay control signal; a ceramic tile color drawing unit 50, the ceramic tile color drawing unit 50 is electrically connected to the second controller 40, and the ceramic tile color drawing unit 50 is used to classify and color the ceramic tiles to be detected according to the delay control signal and the color number value.

[0076] In addition to the features of the above embodiments, this embodiment further defines that: the tile color detection unit 10 communicates with the first controller 20 using a CAN bus.

[0077] In addition to the features of the above embodiment, the present embodiment further defines that: the first controller 20 and the second controller 40 use RS485 bus communication. By using the RS485 bus communication mode between the first controller 20 and the second controller 40, RS485 can communicate over long distances, and the structure is simple and reliable. The second controller 40 can be arranged over long distances relative to the first controller 20, so that the management personnel can remotely manage and control the tile painting process.

[0078] In summary, the automatic coloring device for tiles of the present invention takes pictures of tiles on the production line through the tile color detection unit 10 to obtain a first optical image of the detected tile, queries a standard tile database pre-established according to the first optical image, obtains a corresponding standard tile image, identifies the color difference defect position and color number value of the detected tile, establishes a first rectangular coordinate system with two sides connected by the first optical image as the X-axis and the Y-axis, and reads the position coordinates of the current color difference defect position in the first rectangular coordinate system; connects the encoder 30 through the first controller 20, receives the transmission speed of the detected tile on the production line measured by the encoder 30, and receives the position coordinates and color number value sent by the tile color detection unit 10; receives the position coordinates, transmission speed and color number value sent by the first controller 20 through the second controller 40, substitutes the position coordinates and transmission speed into the formula, and obtains a delay control signal; and drives the tile coloring unit 50 to classify and color the detected tiles by combining the delay control signal and the color difference value, and the machine replaces manual coloring throughout the process, liberating labor, while avoiding wrong painting and missing painting, and improving production efficiency.

[0079] Example 3

[0080] A third embodiment of the present invention provides a tile automatic coloring system, including a memory and a processor, wherein the memory is used to store a tile automatic coloring program, and the processor runs the tile automatic coloring program to enable the tile automatic coloring system to execute the above-mentioned tile automatic coloring method.

[0081] The technical features of the above embodiments may be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0082] The above embodiments only express several implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that for a person of ordinary skill in the art, several modifications and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application shall be subject to the attached claims.

Claims

1. A method for automatically painting tiles, characterized in that: The following steps are involved: Inspecting the ceramic tile, obtaining a first optical image of the ceramic tile, querying a pre-established standard ceramic tile database based on the first optical image, and obtaining the position coordinates and color number values ​​of the ceramic tile under inspection where a color difference defect exists; the specific steps include: taking a first optical image of the ceramic tile, using two adjacent sides of the first optical image as the X-axis and the Y-axis, respectively, and establishing a first rectangular coordinate system based on the first optical image; querying a pre-established standard ceramic tile database based on the first optical image, obtaining a standard ceramic tile image corresponding to the color number of the ceramic tile under inspection, and comparing the first optical image with the standard ceramic tile image to obtain the position coordinates and color number values ​​of the color difference defect of the ceramic tile under inspection in the first rectangular coordinate system; Acquiring the transmission speed of the detected tile on the production line; the specific steps include: capturing the pulse signal of the production line where the detected tile is located by an encoder (30), and calculating in combination with the rotation ratio of the production line and the diameter of the rotating wheel to obtain the transmission speed of the detected tile on the production line; According to the position coordinates and the transmission speed, data calculation is performed to obtain a delay control signal; the specific steps include: substituting the position coordinates and the transmission speed into the formula T=Y / V for calculation, wherein Y is the Y-axis value of the position coordinates, V is the transmission speed of the detected tile on the production line, and T is the delay control signal; The brush module is driven according to the delay control signal and the color number value to classify and mark the detected tiles.

2. The method for automatically painting tiles according to claim 1, characterized in that: The specific steps of driving the brush module according to the delay control signal and the color number value to classify and mark the detected tiles are as follows: The timing starts when the detected tile enters the preset designated position, and after the delay time corresponding to the delay control signal, the brush module is triggered to start; According to the color number value, the brush module classifies and marks the locations where the color difference defects of the detected tiles exist; The brush module is reset. After the brush module completes the classification and color identification, the brush module automatically returns to its initial state.

3. The method for automatically painting tiles according to claim 2, characterized in that: There are multiple color number values, and each of the color number values ​​is assigned a unique classification color symbol, and the classification color symbol is used to distinguish color difference levels.

4. The method for automatically painting tiles according to claim 1, characterized in that: Before the step of performing data calculation to obtain the delay control signal according to the position coordinates and the transmission speed, the step further includes: Determining the validity of a data packet consisting of the position coordinates, the color number value and the transmission speed; If the sum of all bytes of the data packet is equal to zero, it is determined to be valid, and a first signal is generated, and the data calculation process is started according to the first signal.

5. A device for automatically painting tiles, characterized in that: include: A tile color detection unit (10), the tile color detection unit (10) being used to detect tiles, obtain a first optical image of the tiles, and query a pre-established standard tile database based on the first optical image to obtain the position coordinates and color number values ​​of the detected tiles where color difference defects exist; An encoder (30), the encoder (30) being used to capture a pulse signal of a production line; A first controller (20), the first controller (20) being electrically connected to the tile color detection unit (10) and the encoder (30) respectively, and the first controller (20) being used to obtain a transmission speed of the detected tile on the production line; A second controller (40), the second controller (40) being electrically connected to the first controller (20), the second controller (40) being used to perform data calculation according to the position coordinates and the transmission speed to obtain a delay control signal; A tile coloring unit (50), the tile coloring unit (50) being electrically connected to the second controller (40), the tile coloring unit (50) being used to classify and color-mark the detected tiles according to the delayed control signal and the color number value.

6. The automatic tile painting device according to claim 5, characterized in that: The tile color detection unit (10) communicates with the first controller (20) using a CAN bus; and / or The first controller (20) and the second controller (40) communicate using an RS485 bus.

7. A tile automatic color painting system, characterized in that: It comprises a memory and a processor, wherein the memory is used to store a tile automatic coloring program, and the processor runs the tile automatic coloring program to enable the tile automatic coloring system to execute the tile automatic coloring method as described in any one of claims 1-4.

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