Method, device, equipment and storage medium for improving the painting topcoat rhythm

Abstract

The present invention belongs to the technical field of automobile manufacturing, and discloses a method, device, equipment and storage medium for improving the painting topcoat rhythm. The method includes: creating a robot simulation workstation with a digital twin function; running a speed-up program at a target chain speed, and updating the waiting point of the speed-up program according to the simulation situation; performing a simulation test on the speed-up program at the target chain speed, and recording the operation status of the simulated robot in the robot simulation workstation; adjusting the risk points according to the operation status to obtain a first improvement plan; importing the first improvement plan into the robot simulation workstation, updating the waiting point and performing a limit detection test at the current chain speed, and obtaining an adjusted second improvement plan according to the fault detection result; importing the second improvement plan into an on-site production line for online real vehicle debugging; after the adjustment is completed, using the first improvement plan as a mass production program after the speed-up; through the above method, the debugging cycle is greatly reduced after the rhythm is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile manufacturing, and in particular to a method, device, equipment and storage medium for improving the painting topcoat rhythm. Background Art

[0002] The current production rhythm of coating is basically determined after the production line is designed. Generally speaking, there is little room for rhythm improvement, and the workload and difficulty involved are very large, requiring a lot of process verification and debugging. In particular, to improve the rhythm of the topcoat line, it is necessary to first adjust the chain speed of the topcoat line conveyor chain, flash drying oven, and oven settings to ensure process feasibility; then the gun speed, working area / waiting point, and spraying parameters of the robot spraying program should also be adjusted accordingly. However, after making the above changes, it is necessary to re-confirm the single-layer film thickness of each coating, the appearance of the paint film, the color difference, and the quality of the paint film.

[0003] According to the traditional method, in order to avoid the debugging vehicle passing the line to affect production and avoid batch quality problems, the various parameters of the equipment such as the conveyor chain speed must be adjusted in place when the production line is stopped before the relevant single-layer film thickness, appearance, color difference, etc. can be debugged. This requires a lot of manpower and material resources, a large workload, and a long cycle.

[0004] The above contents are only used to assist in understanding the technical solution of the present invention and do not constitute an admission that the above contents are prior art. Summary of the invention

[0005] The main purpose of the present invention is to provide a method, device, equipment and storage medium for improving the painting topcoat rhythm, aiming to solve the problem that the existing technology requires a large amount of manpower and material resources, has a large workload and a long cycle.

[0006] To achieve the above object, the present invention provides a method for improving the painting topcoat beat, the method comprising the following steps:

[0007] A robotics simulation workstation to create digital twin capabilities;

[0008] Running a speed-up program at a target chain speed, and updating a waiting point of the speed-up program according to a simulation situation;

[0009] Performing a simulation test on the speed-up program at the target chain speed, and recording the operation of the simulation robot in the robot simulation workstation;

[0010] Adjust the risk points according to the operation conditions to obtain a first improvement plan;

[0011] Importing the first lifting plan into the robot simulation workstation, performing waiting point update and limit detection test at the current chain speed, and obtaining an adjusted second lifting plan according to the fault detection result;

[0012] The second improvement plan is introduced into the on-site production line for on-line real vehicle debugging;

[0013] After the adjustment is completed, the first improvement plan is used as a mass production program after the speed is increased.

[0014] Optionally, before creating the robot simulation workstation with digital twin function, the process further includes:

[0015] Obtaining a target painting cycle and a target chain speed at the target painting cycle;

[0016] Conduct feasibility analysis on adjustment parameters on the production line according to the target beat;

[0017] When the feasibility analysis is passed, the target operation time of the target spraying robot on the production line is determined according to the target beat;

[0018] Determining a spray gun speed of the target spray robot according to the target operation time;

[0019] A robot simulation workstation with digital twin function is created based on the spray gun speed and motion state.

[0020] Optionally, performing a feasibility analysis on adjustment parameters on the production line according to the target beat includes:

[0021] Conduct a feasibility analysis on flash dry solid content, flash dry temperature setting, conveyor chain speed, fast roller bed setting, skid pitch scheme, topcoat oven temperature setting, topcoat oven baking curve and paint film performance.

[0022] Optionally, when the feasibility analysis is passed, determining the target operation time of the target spraying robot on the production line according to the target beat includes:

[0023] Modify the robot program and use a table to list the matrix table to confirm whether the rhythm of each car model when changing colors meets the requirements;

[0024] After confirming that the beats of the color change connection of each vehicle type meet the requirements, the target operation time of the target spraying robot of each vehicle type after the beat is improved is determined.

[0025] Optionally, adjusting the risk point according to the operation situation to obtain a first improvement plan includes:

[0026] The signal analyzer is used to analyze the angles of each axis, collision conditions, and the motion range limit test of each axis to determine the risk points;

[0027] The risk point is adjusted to achieve zero failure at the target chain speed, and a first improvement plan at the target chain speed is obtained.

[0028] Optionally, performing the waiting point update and limit detection test at the current chain speed, and obtaining an adjusted second improvement plan according to the fault detection result, includes:

[0029] Perform waiting point update and limit detection tests at the current chain speed, add waiting chain value instructions and adjust the angle of the robot's target point in the tool Z direction to adjust the program fault and obtain the second lifting plan.

[0030] Optionally, the step of introducing the second improvement scheme into an on-site production line for on-line real vehicle debugging includes:

[0031] According to the gun speed adjustment ratio and the influence of the paint application rate, a quantitative parameter table is made using a table, the spraying parameters are modified, and the modified brush table is obtained according to the original parameters and the target ratio;

[0032] The parameters of the modified brush table are uploaded, and the parameters of film thickness, appearance and color difference are confirmed through online debugging. Adjustments are made to areas where risks exist, and gradual switching is performed after confirming that there is no obvious difference in quality before and after speed increase.

[0033] In addition, in order to achieve the above-mentioned purpose, the present invention also proposes a coating topcoat rhythm improvement device, the coating topcoat rhythm improvement device comprising:

[0034] Create a simulation module to create a robot simulation workstation with digital twin capabilities;

[0035] The waiting update module is used to run the speed-up program at the target chain speed and update the waiting point of the speed-up program according to the simulation situation;

[0036] A motion recording module, used for performing a simulation test on the speed-up program at the target chain speed, and recording the operation of the simulation robot in the robot simulation workstation;

[0037] A risk adjustment module, used to adjust the risk points according to the operation situation to obtain a first improvement plan;

[0038] A detection and adjustment module, used for importing the first lifting scheme into the robot simulation workstation, performing waiting point update and limit detection test at the current chain speed, and obtaining an adjusted second lifting scheme according to the fault detection result;

[0039] A real vehicle testing module, used to import the second improvement plan into the on-site production line for online real vehicle debugging;

[0040] The scheme determination module is used to use the first improvement scheme as a mass production program after the adjustment is completed.

[0041] In addition, to achieve the above-mentioned objectives, the present invention also proposes a painting topcoat rhythm improvement device, which includes: a memory, a processor, and a painting topcoat rhythm improvement program stored in the memory and executable on the processor, wherein the painting topcoat rhythm improvement program is configured to implement the steps of the painting topcoat rhythm improvement method as described above.

[0042] In addition, to achieve the above-mentioned purpose, the present invention also proposes a storage medium, on which a painting topcoat rhythm improvement program is stored. When the painting topcoat rhythm improvement program is executed by a processor, the steps of the painting topcoat rhythm improvement method as described above are implemented.

[0043] The method for improving the painting topcoat rhythm proposed by the present invention includes: creating a robot simulation workstation with digital twin function; running the speed-up program at the target chain speed, and updating the waiting point of the speed-up program according to the simulation situation; performing simulation test on the speed-up program at the target chain speed, and recording the operation status of the simulated robot in the robot simulation workstation; adjusting the risk points according to the operation status to obtain a first improvement plan; importing the first improvement plan into the robot simulation workstation, updating the waiting point and performing limit detection test at the current chain speed, and obtaining an adjusted second improvement plan according to the fault detection result; importing the second improvement plan into the on-site production line for online real vehicle debugging; after the adjustment is completed, One improvement plan is used as a mass production program after speeding up; since the present invention is a robot simulation workstation with digital twin function, waiting point update and simulation test are performed on the simulation workstation to obtain the first improvement plan under the target chain speed, and the first improvement plan is imported into the simulation workstation, waiting point update, limit detection test and angle adjustment are performed at the current chain speed to obtain the second improvement plan, and the second improvement plan is imported into the on-site production line for online real vehicle debugging. After the adjustment is completed, the first improvement plan is used as the mass production program after speeding up. Compared with the prior art, it is necessary to adjust various parameters such as the conveyor chain speed and other equipment when the production line is stopped before performing related debugging of the single-layer film thickness, appearance, color difference, etc., which can greatly reduce the debugging cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a structural schematic diagram of a coating topcoat beat improvement device in a hardware operating environment involved in an embodiment of the present invention;

[0045] Figure 2 It is a schematic diagram of the process of the first embodiment of the method for improving the topcoat painting rhythm of the present invention;

[0046] Figure 3 It is a schematic flow chart of a second embodiment of the method for improving the topcoat painting rhythm of the present invention;

[0047] Figure 4 It is a schematic diagram of the overall process of the second embodiment of the method for improving the topcoat painting rhythm of the present invention;

[0048] Figure 5 It is a schematic flow chart of a third embodiment of the method for improving the topcoat painting rhythm of the present invention;

[0049] Figure 6 This is a schematic diagram of the functional modules of the first embodiment of the coating topcoat rhythm improvement device of the present invention.

[0050] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0051] It should be understood that the specific embodiments described herein are only used to explain the present invention, and are not used to limit the present invention.

[0052] Reference Figure 1 , Figure 1 This is a schematic diagram of the structure of a coating topcoat rhythm improvement device in the hardware operating environment involved in an embodiment of the present invention.

[0053] like Figure 1 As shown, the coating topcoat beat improvement device may include: a processor 1001, such as a central processing unit (CPU), a communication bus 1002, a user interface 1003, a network interface 1004, and a memory 1005. Wherein, the communication bus 1002 is used to realize the connection communication between these components. The user interface 1003 may include a display screen (Display), an input unit such as a keyboard (Keyboard), and the optional user interface 1003 may also include a standard wired interface and a wireless interface. The network interface 1004 may optionally include a standard wired interface and a wireless interface (such as a wireless fidelity (Wireless-Fidelity, Wi-Fi) interface). The memory 1005 may be a high-speed random access memory (RandomAccess Memory, RAM) memory, or a stable non-volatile memory (Non-Volatile Memory, NVM), such as a disk memory. The memory 1005 may optionally be a storage device independent of the aforementioned processor 1001.

[0054] Those skilled in the art will understand that Figure 1 The structure shown in the figure does not constitute a limitation on the painting topcoat rhythm lifting equipment, and may include more or fewer components than shown in the figure, or a combination of certain components, or a different arrangement of components.

[0055] like Figure 1As shown, the memory 1005 as a storage medium may include an operating system, a network communication module, a user interface module, and a painting topcoat rhythm improvement program.

[0056] exist Figure 1 In the painting topcoat rhythm improvement device shown, the network interface 1004 is mainly used for data communication with the network server; the user interface 1003 is mainly used for data interaction with the user; the processor 1001 and the memory 1005 in the painting topcoat rhythm improvement device of the present invention can be set in the painting topcoat rhythm improvement device, and the painting topcoat rhythm improvement device calls the painting topcoat rhythm improvement program stored in the memory 1005 through the processor 1001, and executes the painting topcoat rhythm improvement method provided by the embodiment of the present invention.

[0057] Based on the above hardware structure, an embodiment of the coating topcoat beat improvement method of the present invention is proposed

[0058] Reference Figure 2 , Figure 2 It is a schematic flow chart of the first embodiment of the method for improving the painting topcoat rhythm of the present invention.

[0059] In this embodiment, the coating topcoat beat improvement method comprises the following steps:

[0060] Step S10: Create a robot simulation workstation with digital twin functions.

[0061] It should be noted that the execution subject of this embodiment is the controller of the coating topcoat beat device, for example, the controller can be used to control the chain speed under the current coating topcoat beat, or can control the spraying time and spray gun speed of the spray robot. Of course, it can also have other functions, which are not limited by this embodiment.

[0062] It is understandable that the digital twin makes full use of data such as physical models, sensor updates, and operation history, integrates multi-disciplinary, multi-physical quantity, multi-scale, and multi-probability simulation processes, and completes mapping in virtual space, thereby reflecting the entire life cycle of the corresponding physical equipment. The digital twin is a concept that transcends reality and can be regarded as a digital mapping system of one or more important, interdependent equipment systems. The digital twin is a generally applicable theoretical and technical system that can be applied in many fields, and is widely used in product design, product manufacturing, medical analysis, engineering construction, and other fields. In this embodiment, the digital twin is used in the field of intelligent manufacturing.

[0063] It should be understood that simulation uses a project model to convert uncertainties specific to a specific level into their impact on the target, which is expressed at the level of the project simulation project as a whole. Project simulation uses a computer model and a risk estimate at a specific level, such as using the Monte Carlo method for simulation, which is not limited in this embodiment.

[0064] In the specific implementation, the workstation is a high-performance computer based on personal computers and distributed network computing, mainly for professional application fields, with powerful data computing and graphics and image processing capabilities, designed and developed to meet the professional fields of engineering design, animation production, scientific research, software development, financial management, information services, simulation and simulation, etc. In this embodiment, a robot simulation workstation is established to simulate the production site environment and the robot on site, so that the simulated robot and the robot on site can ensure that the motion state is consistent when executing spray-related instructions, especially the spraying posture, the angle of each axis, etc.; the online simulation is basically consistent with the on-site debugging state, and there is no need to wait until the end of production to perform real vehicle teaching and program debugging on site, thereby greatly reducing the debugging cycle and workload.

[0065] Step S20: running the speed-up program at the target chain speed, and updating the waiting point of the speed-up program according to the simulation situation.

[0066] It should be noted that the target chain speed refers to the conveyor chain speed of the topcoat line after the topcoat painting rhythm is increased. For example, a production line needs to be accelerated from 32 units / hour to 36 units / hour. The target chain speed is the conveyor chain speed of the topcoat line at a rhythm of 36 units / hour.

[0067] It can be understood that the speed-up program refers to a program that speeds up the original production program and adjusts the parameters. A suffix is ​​added to the name of the newly created spray program to indicate that it is a speed-up program. For example, the original program name is BC1_R11_H7, and the speed-up program name is BC1_R11_H7T. This embodiment does not limit this.

[0068] It should be understood that the waiting point refers to the characteristic point where the spray robot stops. When the conveyor chain temporarily stops or a partial alarm occurs during the spraying process, the spray robot will not immediately stop spraying, but will move to the characteristic point before stopping.

[0069] In the specific implementation, the traditional method is to start the waiting point update of the on-site robot, and then use the theoretical chain speed to simulate to obtain the theoretical chain value when the robot reaches each waiting point, and then use the theoretical chain value as the ideal posture of the robot during the spraying process to guide the movement of the robot. In this embodiment, a digital twin simulation workstation is used, and the simulation site of the simulation workstation is completely consistent with the on-site site. The simulation workstation runs the speed-up program at the target chain speed to perform the waiting point update work.

[0070] Step S30: performing a simulation test on the speed-up program at the target chain speed, and recording the operation status of the simulated robot in the robot simulation workstation.

[0071] It should be noted that the operating conditions refer to risks including the angles of each axis, collision conditions, and limit detection of the motion range of each axis.

[0072] Step S40: adjusting the risk points according to the operating conditions to obtain a first improvement plan.

[0073] It is understandable that the risk point is the critical point where the risk occurs or the key point where the risk exists. In this embodiment, the signal analyzer can be used to analyze the risk points of the speed-up program, and adjustments can be made one by one to eliminate the risk points of crossing the line in advance, without having to wait until the actual vehicle is sprayed on site to discover and adjust.

[0074] In a specific implementation, the speed-up program is simulated and tested at the target chain speed. After adjusting the risk points one by one, it can be ensured that the adjusted speed-up program can achieve zero failure at the target chain speed. The adjusted speed-up program is the first improvement plan.

[0075] Step S50: importing the first lifting scheme into the robot simulation workstation, performing waiting point update and limit detection test at the current chain speed, and obtaining an adjusted second lifting scheme according to the fault detection result.

[0076] It should be understood that the current chain speed refers to the conveyor chain speed of the topcoat line when the topcoat painting rhythm has not been increased. For example, if a production line needs to be accelerated from 32 units / hour to 36 units / hour, the current chain speed is the conveyor chain speed of the topcoat line at a rhythm of 32 units / hour.

[0077] It should be noted that the first lifting plan is imported into the digital twin workstation, and the waiting point update and limit detection test are performed at the current chain speed. The program failure is solved by only adding waiting chain value instructions and adjusting the angle of the robot's target point in the tool Z direction, and the second lifting plan is obtained.

[0078] In the specific implementation, the second improvement plan is a shadow plan of the first improvement plan. The second improvement plan can achieve the same spraying process effect as the first improvement plan, and can be applied to the current chain speed. Therefore, the second improvement plan is imported into the site as a debugging program plan, and the actual vehicle debugging is carried out directly online without adjusting the chain speed after the production is completed and then conducting process debugging.

[0079] Step S60: importing the second improvement plan into the on-site production line for on-line real vehicle debugging.

[0080] In the specific implementation, the actual vehicle debugging is carried out at the current chain speed. The film thickness, color difference and appearance after the speed increase are confirmed, and local adjustments are made. Once it is confirmed that there is no obvious difference in quality before and after the speed increase, the brush table parameters can be uploaded.

[0081] Step S70: After the adjustment is completed, the first improvement plan is used as a mass production program after the speed is increased.

[0082] This embodiment creates a robot simulation workstation with digital twin functions; runs the speed-up program at the target chain speed, and updates the waiting point of the speed-up program according to the simulation situation; performs simulation tests on the speed-up program at the target chain speed, and records the operation of the simulated robot in the robot simulation workstation; adjusts the risk points according to the operation situation to obtain a first improvement plan; imports the first improvement plan into the robot simulation workstation, updates the waiting points and performs limit detection tests at the current chain speed, and obtains the adjusted second improvement plan according to the fault detection results; imports the second improvement plan into the on-site production line for online real vehicle debugging; after the adjustment is completed, the first improvement plan is used as the mass production program after the speed-up. Through the above method, the debugging cycle is greatly reduced after the beat is improved.

[0083] In one embodiment, if Figure 3 The second embodiment of the method for improving the topcoat painting cycle of the present invention is proposed based on the first embodiment. Before step S10, the method includes:

[0084] Step S100: obtaining a target painting rhythm and a target chain speed under the target painting rhythm.

[0085] Step S200: Perform a feasibility analysis on adjustment parameters on the production line according to the target cycle time.

[0086] It should be noted that the feasibility analysis requires confirmation of adjustment parameters such as flash dry solid content, flash dry temperature setting, conveyor chain speed, fast roller bed setting, slide pitch scheme, topcoat oven temperature setting, topcoat oven baking curve, paint film performance, etc., and this embodiment does not limit this.

[0087] Step S300: When the feasibility analysis is passed, the target operation time of the target spraying robot on the production line is determined according to the target beat.

[0088] It should be understood that the target spraying robot is a robot that sprays the target vehicle model. It is necessary to establish a vehicle model code that the robot can recognize to distinguish the mass production status of the target vehicle model from the speed-up debugging status, which will neither affect normal production nor the debugging progress.

[0089] It can be understood that the operation time is the time required for the theoretical cycle minus the time required for color change and cleaning, that is, the robot operation time = theoretical cycle time - color change and cleaning time.

[0090] In the specific implementation, a matrix table is used to confirm whether the beat of each model meets the requirements when changing colors; after confirming that the beat of each model meets the requirements when changing colors, the target operation time of the target spray robot of each model after improving the beat is determined.

[0091] Step S400: determining the spray gun speed of the target spray robot according to the target operation time.

[0092] It should be noted that the spray gun speed is adjusted proportionally on the original program so that the spray operation time of each robot is within the target time, and the local spray area may not be adjusted according to the quality requirements such as color difference and appearance. For example, a special operation time calculation tool is used to calculate the operation time after speeding up, and the gun speed is adjusted proportionally so that the robot spray operation time is within the target time. This embodiment does not limit this.

[0093] Step S500: Create a robot simulation workstation with digital twin functions according to the spray gun speed and motion state.

[0094] In the specific implementation, the robot simulation workstation ensures that the motion state of the simulated robot and the on-site robot is consistent when executing spray-related instructions, especially the spraying posture, angles of each axis, etc., so that the online simulation and on-site debugging state are basically consistent. There is no need to wait until the end of production to carry out real vehicle teaching and program debugging on site, which greatly reduces the debugging cycle and workload.

[0095] This embodiment obtains the target beat of painting and the target chain speed under the target beat of painting; performs a feasibility analysis on the adjustment parameters on the production line according to the target beat; when the feasibility analysis is passed, determines the target operation time of the target spray robot on the production line according to the target beat; determines the spray gun speed of the target spray robot according to the target operation time; creates a robot simulation workstation with digital twin function according to the spray gun speed and motion state. Since this embodiment performs a feasibility analysis based on the target beat and target parameters, determines the target operation time after the feasibility analysis, and then determines the spray gun speed according to the target operation time, and finally creates a simulation workstation, there is no need to wait until the end of production to perform real vehicle teaching and program debugging on site, which greatly reduces the debugging cycle and workload.

[0096] Figure 4 It is a schematic diagram of the overall process of the second embodiment of the method for improving the painting topcoat rhythm of the present invention.

[0097] It should be noted that the speed-up program plan A is the first improvement plan, and the speed-up program plan B is the second improvement plan.

[0098] It should be understood that Figure 4 Step 9: Adjust the alarm fault of plan A to improve the risk point. After adjusting the risk points one by one, when the program after speed adjustment achieves zero fault at the target chain speed, proceed to step 10; if the program after speed adjustment can still have faults at the target chain speed, return to step 8.

[0099] Understandably, Figure 4 Step 10: Use Scheme A to make shadow Scheme B for real vehicle testing. Confirm the film thickness, color difference, and appearance after speed increase, make local adjustments, and confirm that there is no obvious difference in quality before and after speed increase, and proceed to Step 11; if it is confirmed that there is an obvious difference in quality before and after speed increase, return to Step 7.

[0100] In one embodiment, if Figure 5 Based on the first embodiment, a third embodiment of the method for improving the topcoat painting cycle of the present invention is proposed. Step S60 includes:

[0101] Step S610: According to the gun speed adjustment ratio and the influence of the paint application rate, a quantitative parameter table is prepared using a table, the spraying parameters are modified, and a modified brush table is obtained according to the original parameters and the target ratio.

[0102] It should be noted that the gun speed adjustment ratio refers to proportionally adjusting the spray gun speed based on the original program so that the spraying operation time of each robot is within the target time. The spray gun speed is not adjusted during the process of introducing the second improvement plan for actual vehicle debugging.

[0103] It should be understood that the brush table is a parameter file that defines the paint output, rotation speed, shaping air, electrostatic high voltage, etc. during spraying. The parameter file defines several groups of spraying parameters, and a certain group of parameters can be called for spraying at different positions of the vehicle body.

[0104] In a specific implementation, the modified brush table is obtained based on the original parameters and the target ratio. For example, a table tool is created, the brush table is imported into the tool, and the speed increase ratio is input. The paint output of each group after the speed increase can be automatically calculated, and the modified brush table is generated as the parameters after the speed increase. This embodiment does not impose any restrictions on this.

[0105] Step S620: Upload the parameters of the modified brush table, confirm the parameters of film thickness, appearance and color difference through online debugging, adjust the areas where there are risks, and gradually switch after confirming that there is no obvious difference in quality before and after speed increase.

[0106] It should be noted that gradual switching means gradually replacing the spraying parameters in the brush table. Different positions of the vehicle body correspond to a set of parameters for spraying. The replaced spraying parameters make the corresponding positions of the vehicle body have no obvious difference in quality before and after speeding up. For example, the front position corresponds to spraying parameter group 1. The film thickness, color difference, and appearance after speeding up are confirmed, and the data of spraying parameter group 1 are adjusted. After adjustment, there is no obvious difference in quality before and after speeding up at the front position. The data of spraying parameter group 1 that has not been adjusted in the brush table is replaced with the data of spraying parameter group 1 after adjustment.

[0107] In this embodiment, according to the influence of the gun speed adjustment ratio and the paint application rate, a quantitative parameter table is prepared using a table, the spraying parameters are modified, and a modified brush table is obtained according to the original parameters and the target ratio; the parameters of the modified brush table are uploaded, and the parameters of the film thickness, appearance and color difference are confirmed through online debugging, and the places where there are risks are adjusted, and the quality before and after the speed increase is confirmed to be no significant difference, and then the switch is gradually made. Since the spraying parameters are modified according to the influence of the gun speed adjustment ratio and the paint application rate in this embodiment, the modified brush table is obtained according to the original parameters and the target ratio, and finally the parameters of the film thickness, appearance and color difference are confirmed through online debugging, and the places where there are risks are adjusted, so as to upload the brush table parameters with no significant difference in quality before and after the speed increase.

[0108] In addition, an embodiment of the present invention further proposes a storage medium, on which a painting topcoat rhythm improvement program is stored. When the painting topcoat rhythm improvement program is executed by a processor, the steps of the painting topcoat rhythm improvement method as described above are implemented.

[0109] Since the storage medium adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought by the technical solutions of the above embodiments, which will not be described one by one here.

[0110] In addition, refer to Figure 6 The embodiment of the present invention further provides a coating topcoat rhythm improvement device, the coating topcoat rhythm improvement device comprising:

[0111] Create a simulation module 10, which is used to create a robot simulation workstation with digital twin functions.

[0112] It should be noted that the device of this embodiment is deployed in the controller of the coating topcoat beat equipment, for example, the controller can be used to control the chain speed under the current coating topcoat beat, or can control the spraying time and spray gun speed of the spray robot. Of course, it can also have other functions, which are not limited by this embodiment.

[0113] It is understandable that the digital twin makes full use of data such as physical models, sensor updates, and operation history, integrates multi-disciplinary, multi-physical quantity, multi-scale, and multi-probability simulation processes, and completes mapping in virtual space, thereby reflecting the entire life cycle of the corresponding physical equipment. The digital twin is a concept that transcends reality and can be regarded as a digital mapping system of one or more important, interdependent equipment systems. The digital twin is a generally applicable theoretical and technical system that can be applied in many fields, and is widely used in product design, product manufacturing, medical analysis, engineering construction, and other fields. In this embodiment, the digital twin is used in the field of intelligent manufacturing.

[0114] It should be understood that simulation uses a project model to convert uncertainties specific to a specific level into their impact on the target, which is expressed at the level of the project simulation project as a whole. Project simulation uses a computer model and a risk estimate at a specific level, such as using the Monte Carlo method for simulation, which is not limited in this embodiment.

[0115] In the specific implementation, the workstation is a high-performance computer based on personal computers and distributed network computing, mainly for professional application fields, with powerful data computing and graphics and image processing capabilities, designed and developed to meet the professional fields of engineering design, animation production, scientific research, software development, financial management, information services, simulation and simulation, etc. In this embodiment, a robot simulation workstation is established to simulate the production site environment and the robot on site, so that the simulated robot and the robot on site can ensure that the motion state is consistent when executing spray-related instructions, especially the spraying posture, the angle of each axis, etc.; the online simulation is basically consistent with the on-site debugging state, and there is no need to wait until the end of production to perform real vehicle teaching and program debugging on site, thereby greatly reducing the debugging cycle and workload.

[0116] The waiting update module 20 is used to run the speed-up program at the target chain speed and update the waiting point of the speed-up program according to the simulation situation.

[0117] It should be noted that the target chain speed refers to the conveyor chain speed of the topcoat line after the topcoat painting rhythm is increased. For example, a production line needs to be accelerated from 32 units / hour to 36 units / hour. The target chain speed is the conveyor chain speed of the topcoat line at a rhythm of 36 units / hour.

[0118] It can be understood that the speed-up program refers to a program that speeds up the original production program and adjusts the parameters. A suffix is ​​added to the name of the newly created spray program to indicate that it is a speed-up program. For example, the original program name is BC1_R11_H7, and the speed-up program name is BC1_R11_H7T. This embodiment does not limit this.

[0119] It should be understood that the waiting point refers to the characteristic point where the spray robot stops. When the conveyor chain temporarily stops or a partial alarm occurs during the spraying process, the spray robot will not immediately stop spraying, but will move to the characteristic point before stopping.

[0120] In the specific implementation, the traditional method is to start the waiting point update of the on-site robot, and then use the theoretical chain speed to simulate to obtain the theoretical chain value when the robot reaches each waiting point, and then use the theoretical chain value as the ideal posture of the robot during the spraying process to guide the movement of the robot. In this embodiment, a digital twin simulation workstation is used, and the simulation site of the simulation workstation is completely consistent with the on-site site. The simulation workstation runs the speed-up program at the target chain speed to perform the waiting point update work.

[0121] The motion recording module 30 is used to perform a simulation test on the speed-up program at the target chain speed and record the operation status of the simulated robot in the robot simulation workstation.

[0122] It should be noted that the operating conditions refer to risks including the angles of each axis, collision conditions, and limit detection of the motion range of each axis.

[0123] The risk adjustment module 40 is used to adjust the risk points according to the operation situation to obtain a first improvement plan.

[0124] It is understandable that the risk point is the critical point where the risk occurs or the key point where the risk exists. In this embodiment, the signal analyzer can be used to analyze the risk points of the speed-up program, and adjustments can be made one by one to eliminate the risk points of crossing the line in advance, without having to wait until the actual vehicle is sprayed on site to discover and adjust.

[0125] In a specific implementation, the speed-up program is simulated and tested at the target chain speed. After adjusting the risk points one by one, it can be ensured that the adjusted speed-up program can achieve zero failure at the target chain speed. The adjusted speed-up program is the first improvement plan.

[0126] The detection and adjustment module 50 is used to import the first lifting plan into the robot simulation workstation, perform waiting point update and limit detection test at the current chain speed, and obtain an adjusted second lifting plan according to the fault detection result.

[0127] It should be understood that the current chain speed refers to the conveyor chain speed of the topcoat line when the topcoat painting rhythm has not been increased. For example, if a production line needs to be accelerated from 32 units / hour to 36 units / hour, the current chain speed is the conveyor chain speed of the topcoat line at a rhythm of 32 units / hour.

[0128] It should be noted that the first lifting plan is imported into the digital twin workstation, and the waiting point update and limit detection test are performed at the current chain speed. The program failure is solved by only adding waiting chain value instructions and adjusting the angle of the robot's target point in the tool Z direction, and the second lifting plan is obtained.

[0129] In the specific implementation, the second improvement plan is a shadow plan of the first improvement plan. The second improvement plan can achieve the same spraying process effect as the first improvement plan, and can be applied to the current chain speed. Therefore, the second improvement plan is imported into the site as a debugging program plan, and the actual vehicle debugging is carried out directly online without adjusting the chain speed after the production is completed and then conducting process debugging.

[0130] The real vehicle testing module 60 is used to import the second improvement plan into the on-site production line for online real vehicle debugging.

[0131] In the specific implementation, the actual vehicle debugging is carried out at the current chain speed. The film thickness, color difference and appearance after the speed increase are confirmed, and local adjustments are made. Once it is confirmed that there is no obvious difference in quality before and after the speed increase, the brush table parameters can be uploaded.

[0132] The scheme determination module 70 is used to use the first improvement scheme as a mass production program after the adjustment is completed.

[0133] This embodiment creates a robot simulation workstation with digital twin functions; runs the speed-up program at the target chain speed, and updates the waiting point of the speed-up program according to the simulation situation; performs simulation tests on the speed-up program at the target chain speed, and records the operation of the simulated robot in the robot simulation workstation; adjusts the risk points according to the operation situation to obtain a first improvement plan; imports the first improvement plan into the robot simulation workstation, updates the waiting points and performs limit detection tests at the current chain speed, and obtains the adjusted second improvement plan according to the fault detection results; imports the second improvement plan into the on-site production line for online real vehicle debugging; after the adjustment is completed, the first improvement plan is used as the mass production program after the speed-up. Through the above method, the debugging cycle is greatly reduced after the beat is improved.

[0134] It should be noted that the workflow described above is merely illustrative and does not limit the scope of protection of the present invention. In practical applications, technicians in this field can select part or all of them according to actual needs to achieve the purpose of the present embodiment, and no limitation is made here.

[0135] In addition, for technical details that are not described in detail in this embodiment, reference can be made to the method for improving the painting topcoat rhythm provided in any embodiment of the present invention, and will not be repeated here.

[0136] In one embodiment, the simulation creation module 10 is also used to obtain the target beat of painting and the target chain speed under the target beat of painting; perform a feasibility analysis on the adjustment parameters on the production line according to the target beat; when the feasibility analysis passes, determine the target operation time of the target spray robot on the production line according to the target beat; determine the spray gun speed of the target spray robot according to the target operation time; and create a robot simulation workstation with digital twin function according to the spray gun speed and motion state.

[0137] In one embodiment, the creation simulation module 10 is also used to perform feasibility analysis on flash dry solid content, flash dry temperature setting, conveyor chain speed, fast roller bed setting, slide pitch scheme, temperature setting of topcoat oven, baking curve of topcoat oven and paint film performance.

[0138] In one embodiment, the creation simulation module 10 is also used to modify the robot program, and a matrix table is used to confirm whether the beat of each vehicle model meets the requirements when changing colors and connecting. After confirming that the beat of each vehicle model meets the requirements when changing colors and connecting, the target operation time of the target spray robot of each vehicle model after improving the beat is determined.

[0139] In one embodiment, the risk adjustment module 40 is also used to analyze the angles of each axis, collision conditions and the limit tests of the motion range of each axis through a signal analyzer to obtain risk points; adjust the risk points to achieve zero failure at the target chain speed, and obtain the first improvement plan at the target chain speed.

[0140] In one embodiment, the detection and adjustment module 50 is also used to perform waiting point updates and limit detection tests at the current chain speed, and program fault adjustments are performed by adding waiting chain value instructions and adjusting the angle of the robot's target point in the tool Z direction to obtain a second lifting plan.

[0141] In one embodiment, the real vehicle test module 60 uses a table to prepare a quantitative parameter table according to the influence of the gun speed adjustment ratio and the paint application rate, modifies the spraying parameters, and obtains a modified brush table according to the original parameters and the target ratio; uploads the parameters of the modified brush table, confirms the parameters of the film thickness, appearance and color difference through online debugging, adjusts the places where there are risks, and gradually switches after confirming that there is no obvious difference in quality before and after speeding up.

[0142] Other embodiments or implementation methods of the coating topcoat rhythm improvement device described in the present invention can refer to the above-mentioned method embodiments and are not repeated here.

[0143] In addition, it should be noted that, in this article, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or system including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or system. In the absence of further restrictions, an element defined by the sentence "comprises a ..." does not exclude the existence of other identical elements in the process, method, article or system including the element.

[0144] The serial numbers of the above embodiments of the present invention are only for description and do not represent the advantages or disadvantages of the embodiments.

[0145] Through the description of the above implementation methods, those skilled in the art can clearly understand that the above-mentioned embodiment methods can be implemented by means of software plus a necessary general hardware platform, and of course by hardware, but in many cases the former is a better implementation method. Based on such an understanding, the technical solution of the present invention, or the part that contributes to the prior art, can be embodied in the form of a software product, which is stored in a storage medium (such as a read-only memory (ROM) / RAM, a magnetic disk, or an optical disk), and includes a number of instructions for a terminal device (which can be a mobile phone, a computer, a server, or a network device, etc.) to execute the methods described in each embodiment of the present invention.

[0146] The above are only preferred embodiments of the present invention, and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A method for improving the painting topcoat rhythm, characterized in that: The method comprises the following steps: A robotics simulation workstation to create digital twin capabilities; Running a speed-up program at a target chain speed, and updating a waiting point of the speed-up program according to a simulation situation; Performing a simulation test on the speed-up program at the target chain speed, and recording the operation of the simulation robot in the robot simulation workstation; Adjust the risk points according to the operation conditions to obtain a first improvement plan; Importing the first lifting plan into the robot simulation workstation, performing waiting point update and limit detection test at the current chain speed, and obtaining an adjusted second lifting plan according to the fault detection result; The second improvement plan is introduced into the on-site production line for on-line real vehicle debugging; After the adjustment is completed, the first improvement plan is used as a mass production program after the speed is increased.

2. The method according to claim 1, characterized in that Before creating the robot simulation workstation with digital twin function, it also includes: Obtaining a target painting cycle and a target chain speed at the target painting cycle; Conduct feasibility analysis on adjustment parameters on the production line according to the target beat; When the feasibility analysis is passed, the target operation time of the target spraying robot on the production line is determined according to the target beat; Determining a spray gun speed of the target spray robot according to the target operation time; A robot simulation workstation with digital twin function is created based on the spray gun speed and motion state.

3. The method according to claim 2, characterized in that The feasibility analysis of the adjustment parameters on the production line according to the target beat includes: Conduct a feasibility analysis on flash dry solid content, flash dry temperature setting, conveyor chain speed, fast roller bed setting, skid pitch scheme, topcoat oven temperature setting, topcoat oven baking curve and paint film performance.

4. The method according to claim 2, characterized in that When the feasibility analysis is passed, determining the target operation time of the target spraying robot on the production line according to the target beat includes: Modify the robot program and use a table to list the matrix table to confirm whether the rhythm of each car model when changing colors meets the requirements; After confirming that the beats of the color change connection of each vehicle type meet the requirements, the target operation time of the target spraying robot of each vehicle type after the beat is improved is determined.

5. The method according to claim 1, characterized in that The step of adjusting the risk points according to the operation conditions to obtain a first improvement plan includes: The signal analyzer is used to analyze the angles of each axis, collision conditions, and the motion range limit test of each axis to determine the risk points; The risk point is adjusted to achieve zero failure at the target chain speed, and a first improvement plan at the target chain speed is obtained.

6. The method according to claim 1, characterized in that The waiting point update and limit detection test are performed at the current chain speed, and the adjusted second improvement plan is obtained according to the fault detection result, including: Perform waiting point update and limit detection tests at the current chain speed, add waiting chain value instructions and adjust the angle of the robot's target point in the tool Z direction to adjust the program fault and obtain the second lifting plan.

7. The method according to claim 1, characterized in that The step of introducing the second improvement scheme into the on-site production line for on-line real vehicle debugging comprises: According to the gun speed adjustment ratio and the influence of the paint application rate, a quantitative parameter table is made using a table, the spraying parameters are modified, and the modified brush table is obtained according to the original parameters and the target ratio; The parameters of the modified brush table are uploaded, and the parameters of film thickness, appearance and color difference are confirmed through online debugging. Adjustments are made to areas where risks exist, and gradual switching is performed after confirming that there is no obvious difference in quality before and after speed increase.

8. A coating topcoat rhythm improvement device, characterized in that: The coating topcoat rhythm lifting device comprises: Create a simulation module to create a robot simulation workstation with digital twin capabilities; The waiting update module is used to run the speed-up program at the target chain speed and update the waiting point of the speed-up program according to the simulation situation; A motion recording module, used for performing a simulation test on the speed-up program at the target chain speed, and recording the operation of the simulation robot in the robot simulation workstation; A risk adjustment module, used to adjust the risk points according to the operation situation to obtain a first improvement plan; A detection and adjustment module, used for importing the first lifting scheme into the robot simulation workstation, performing waiting point update and limit detection test at the current chain speed, and obtaining an adjusted second lifting scheme according to the fault detection result; A real vehicle testing module, used to import the second improvement plan into the on-site production line for online real vehicle debugging; The scheme determination module is used to use the first improvement scheme as a mass production program after the adjustment is completed.

9. A coating topcoat rhythm improvement device, characterized in that: The device comprises: a memory, a processor and a painting topcoat rhythm improvement program stored in the memory and executable on the processor, wherein the painting topcoat rhythm improvement program is configured to implement the steps of the painting topcoat rhythm improvement method as described in any one of claims 1 to 7.

10. A storage medium, characterized in that: The storage medium stores a painting topcoat rhythm improvement program, and when the painting topcoat rhythm improvement program is executed by the processor, the steps of the painting topcoat rhythm improvement method as described in any one of claims 1 to 7 are implemented.

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