Automatic spraying machine and automatic spraying method for interior decoration wall based on machine vision

Abstract

The present invention relates to indoor decoration equipment, and specifically discloses an automatic spraying machine and an automatic spraying method for indoor decoration walls based on machine vision. The automatic spraying machine includes a spraying unit, a secondary frame and a primary frame; through two-stage lifting and controlling the movement stroke of the spraying mechanism inside the two-stage lifting mechanism, the automatic spraying machine occupies less space while maintaining high flexibility compared to the automatic spraying equipment of a mechanical arm, and is very suitable for indoor environments with relatively compact space. In addition, the design and structure of the two-stage lifting frame are more concise, intuitive, and square than the spraying of a mechanical arm, and are more helpful in ensuring the stability during the spraying process; using the automatic spraying method, compared with the current spraying of a mechanical arm robot, the calling parameters are more concise and clear, making the spraying machine more concise and reliable, and more convenient to maintain.

Description

Technical Field

[0001] The invention relates to indoor decoration equipment, in particular to an automatic wall spraying machine and an automatic indoor decoration wall spraying method based on machine vision. Background Art

[0002] In interior decoration, wall spraying is a key process. Traditional spraying methods mainly rely on manual operation, which inevitably leads to many problems. For example, when workers hold spray guns for spraying, they need to constantly adjust the direction, angle, distance, etc. of the spray guns, which requires high operating skills and experience of workers; affected by visual deviation, the quality of manual spraying is generally poor, and the wall paint is sprayed unevenly or unevenly; when spraying indoors, the air flow is poor and the pollution is large, and long-term operation will have a very adverse effect on the health of workers. Moreover, compared with automatic spraying devices, manual spraying is less efficient and it is difficult to meet the needs of large-scale or rapid construction. With the advancement of science and technology and the development of the times, automated and intelligent spraying devices will gradually replace traditional manual spraying and become an important means of modern industrial intelligence, promoting the construction and decoration industry to develop in a more green and efficient direction.

[0003] Among them, the automatic spraying machine using a mechanical arm is selected as a solution to replace manual spraying because of its high degree of automation. The current mechanical arm automatic spraying machine or robot has multiple joints and can move freely in multiple dimensions. The spraying is automatically sprayed by programming, but the purchase and maintenance cost of the mechanical arm automatic spraying machine is high. Although the mechanical arm can move flexibly within a certain range, its adaptability is still limited for complex indoor environments, especially special structures such as corners, and the volume of the mechanical arm is not only large, but the mechanical arm needs to perform a variety of operations such as stretching, bending, and shaking left and right. For indoor environments with limited space, its movement stroke or the trajectory of the mechanical arm has already occupied a lot of space. Although it is applicable to the decoration of large industrial sites or commercial sites, its applicability is further reduced for indoor decoration with a relatively compact space. Therefore, there is a need for an indoor decoration automatic spraying equipment with higher adaptability that is applicable to compact spaces, occupies less space, and still maintains high flexibility. Summary of the invention

[0004] In response to the above-mentioned technical problems, the present invention provides an automatic sprayer and an automatic spraying method for interior decoration walls based on machine vision. The automatic sprayer, through two-stage lifting and controlling the movement stroke of the spraying mechanism entirely inside the two-stage lifting mechanism, can achieve flexible lifting in the vertical direction while the spraying mechanism will not occupy more redundant space during spraying, so that the overall height of the equipment is adjustable and the volume is smaller, which can improve the adaptability and transportation convenience of different working environments (such as different wall heights, different indoor space sizes), and is more suitable for compact and smaller indoor spaces.

[0005] The present invention provides an automatic spraying machine, comprising a spraying unit, a secondary frame and a primary frame; the spraying unit is used to spray the wall; the spraying unit is arranged inside the frame of the secondary frame, and the frame of the secondary frame is provided with a secondary lifting mechanism that enables the spraying unit to be lifted and lowered along the Z-axis direction of the secondary frame; the secondary frame is arranged inside the frame of the primary frame, and the frame of the primary frame is provided with a primary lifting mechanism that enables the secondary frame to be lifted and lowered along the Z-axis direction of the primary frame;

[0006] The spraying unit includes a spraying base connected to the secondary frame through a secondary lifting mechanism and a spraying part that can be movably arranged on the spraying base along the X and Y axes for spraying the wall, and the orthographic projection of the movable track of the connection between the spraying part and the spraying base is located inside the frame of the secondary frame. The orthographic projection direction here is from top to bottom.

[0007] The automatic spraying machine adopts a secondary frame and a primary frame embedded in the manner to constrain the lifting stroke of the entire frame in the Z-axis direction, and then determines the lifting stroke of the spraying unit in the entire Z-axis direction. This two-stage lifting method greatly improves the spraying range in the height direction. At the same time, the entire spraying unit is arranged on the inner side of the secondary frame, and the spraying base is used to determine that the stroke of the entire spraying part in the X-axis and Y-axis directions is all inside the secondary frame. In this way, compared with the automatic spraying equipment of the robotic arm, the automatic spraying machine maintains a higher flexibility while occupying a smaller space, and is very suitable for indoor environments with relatively compact space. In addition, the design and structure of the two-stage lifting frame are more concise, intuitive, and square than the robotic arm spraying, and are also more helpful in ensuring stability during the spraying process.

[0008] Furthermore, the secondary rack includes: a secondary frame, a secondary slide rail, and a secondary driving mechanism.

[0009] The secondary frame is connected to the primary frame through a primary lifting mechanism, so that the secondary frame can be lifted and lowered along the Z-axis direction of the primary frame; the secondary slide rail is arranged on the secondary frame and along the Z-axis direction; the secondary driving mechanism is arranged on the secondary frame, and the secondary driving mechanism is connected to the spray base, so as to drive the spray base to perform lifting movement along the Z-axis direction.

[0010] Furthermore, the secondary frame includes secondary poles and secondary pole connectors; the secondary poles are arranged along the Z-axis direction, and the secondary slide rails are set on the secondary poles; the top ends of multiple secondary poles are connected by the secondary pole connectors, so that the secondary frame forms a frame structure supported by multiple secondary poles.

[0011] Furthermore, the primary frame includes a base plate and a primary pole; the base plate is supported by electric wheels; the primary pole is arranged above the base plate along the Z-axis direction, and the primary pole is connected to the secondary frame through a primary lifting mechanism to drive the secondary frame to perform lifting actions along the Z-axis direction. The electric wheels here, that is, each wheel is equipped with an independent steering mechanism, which can be controlled individually by the controller and receive instructions uniformly to perform maneuvering tasks, such as turning on the spot to change direction.

[0012] Furthermore, the spraying part includes a spray head and a spraying frame; the spray head is used to spray the wall surface; the spraying frame is arranged on the spraying base, the spray head is arranged on the spraying frame, and the spraying frame is used to drive the spray head to selectively move along the X-axis or / and the Y-axis;

[0013] Wherein, an image acquisition unit arranged parallel to the direction of the nozzle is provided on the nozzle, and the image acquisition unit is used to collect image data of the corresponding area of ​​the nozzle; a projection unit is provided on the spraying machine frame or the spraying base;

[0014] In the horizontal direction perpendicular to the spraying of the nozzle or the horizontal direction perpendicular to the direction of the lens of the image acquisition unit, an ultrasonic sensor is respectively arranged on both sides of the nozzle and the nozzle is located at the midpoint of the line between the two ultrasonic sensors, and the ultrasonic sensor is used to obtain the distance data from the area in front of the nozzle to the ultrasonic sensor;

[0015] The automatic spraying machine for indoor decoration walls also includes a controller for controlling the nozzle and the spraying machine frame. The controller is respectively connected to the electric wheel and the ultrasonic sensor for controlling the electric wheel to drive the automatic spraying machine for indoor decoration walls to perform a specified translation according to the distance data. The specified translation is a tangent translation from the midpoint of the line connecting the two ultrasonic sensors to the wall point where the orthographic projection of the wall is located. The controller is also respectively connected to the image acquisition unit and the projection unit for controlling the projection unit to project onto the wall and controlling the image acquisition unit to obtain image data on the wall. The above controller is also connected to the primary and secondary lifting mechanisms at the same time to control the lifting action of the entire spraying machine.

[0016] Furthermore, the nozzle includes a nozzle fixing frame and a nozzle; the nozzle fixing frame is rotatably arranged on the spray machine frame, so that the nozzle fixing frame can rotate around the X-axis or the Y-axis; the nozzle is arranged on the nozzle fixing frame, so as to spray the wall; the image acquisition unit is arranged on the upper side of the nozzle fixing frame and corresponds to the nozzle on the nozzle fixing frame up and down; at least two ultrasonic sensors are respectively arranged on both sides of the nozzle fixing frame; the direction of the ultrasonic sensor, the direction of the nozzle, and the direction of the image acquisition unit are all arranged in parallel.

[0017] Furthermore, both the secondary frame and the primary frame are straight quadrangular prism frames; the nozzle is oriented perpendicular to the plane where one side surface of the primary frame is located.

[0018] Furthermore, the cross-sections of the secondary frame and the primary frame in the Z-axis direction are square; and the side surfaces of the secondary frame are parallel to the side surfaces of the primary frame.

[0019] Furthermore, a material box is arranged in the spray base, and the spray head is connected to the material box for spraying the spray material in the material box from the spray head.

[0020] Furthermore, a dust collection assembly is also provided on the first-stage frame, and the dust collection assembly includes a dust collection piece and an air pump connected to the air outlet of the vacuum cleaner;

[0021] The dust collecting part is arranged at the lower end of the spraying base, and the air inlet of the dust collecting part faces the same direction as the spraying direction; the air outlet of the air pump is connected with the material box through the air filtering device.

[0022] Furthermore, the nozzle is connected to the spray machine frame through a pitch rotation mechanism, so that the nozzle can rotate around the X-axis direction (the width direction of the spray machine).

[0023] Furthermore, the pitch rotation angle of the nozzle is -30°~90°. This can achieve a certain pitch rotation, especially the nozzle can be adjusted in pitch, which is convenient for spraying in complex positions such as horizontal corners and top ceilings.

[0024] Furthermore, the nozzle is a single wide-angle spray nozzle (about 130-160° or 150° wide angle), which improves the uniformity of spraying and avoids the spraying interference phenomenon (similar to the ripple superposition effect) caused by the one-way multi-nozzle design of the current spraying equipment.

[0025] Another aspect of the present invention further provides an automatic spraying method for indoor decoration walls based on machine vision, using the automatic spraying machine for indoor decoration walls of the above aspect, the automatic spraying method for indoor decoration walls includes the following operations:

[0026] A coordinate system is established with the center of the spraying machine, the width direction of the spraying machine is the X-axis direction, the forward spraying direction of the spraying machine is the Y-axis direction, and the height direction of the spraying machine is the Z-axis direction;

[0027] Move the indoor decoration wall automatic spraying machine to the wall to be sprayed, so that the spraying part faces the wall to be sprayed;

[0028] An image acquisition unit is used to capture a wall image, and a controller is used to extract specified features in the wall image, and coordinate data of the specified features are calculated; the specified features include cracks, color difference blocks, and color difference edges;

[0029] Use ultrasonic sensors to obtain the distances Y1 and Y2 between the two ultrasonic sensors and the wall, and set the angle change threshold ΔY;

[0030] When |Y1-Y2|≤ΔY, the spraying operation is performed, and after the spraying is completed, the automatic spraying machine for indoor decoration walls is moved to the next spraying position according to the extracted color difference edge line;

[0031] When |Y1-Y2|>ΔY, the controller controls the electric wheel to drive the automatic sprayer for interior decoration walls to rotate around the Z axis, so that |Y1-Y2|≤ΔY, and then the spraying operation is performed. After the spraying is completed, the automatic sprayer for interior decoration walls is moved to the next spraying position according to the extracted color difference edge line.

[0032] The automatic spraying method for indoor decoration walls adopts a special and concise path planning method in the design scheme. Only by relying on the distance data obtained by the ultrasonic sensor for detecting the spraying distance, the path planning and direction control of the entire sprayer can be concise. Specifically, at least two ultrasonic sensors are arranged on both sides of the nozzle fixing frame in the scheme, and their main function is to monitor the distance data between the area in front of the nozzle and the ultrasonic sensor in real time. These data are not only used to maintain a constant distance between the nozzle and the wall, but also by obtaining the distance information measured by at least two ultrasonic sensors in real time, it can ensure that the spraying surface of the first-stage frame or the entire sprayer is always parallel to the wall. This arrangement ensures that on the translation path of the entire sprayer, the spraying surface of the first-stage frame or the entire sprayer can be used as a section of the corresponding wall, thereby significantly reducing the complexity of the wall faced by the image acquisition unit during the spraying process, and thereby reducing the complexity of the parameters required to be called during spraying. At the same time, compared with the current robotic arm spraying equipment that uses radar and rangefinders or performs environmental perception calculations and path planning in advance, this solution is aimed at wall spraying and does not require research on complex path calculations and navigation algorithms, making the wall translation function clearer, simpler and more reliable.

[0033] Furthermore, before spraying, the connection between the spraying part and the spraying base is moved to an initial position, and the initial position satisfies the following conditions:

[0034] Condition P1 is that the distance from the connection point to the plane in the Z-axis direction where the edge of the spray base close to the wall is located is greater than 0;

[0035] During spraying, the nozzle starts spraying from the side of the spray base close to the color difference edge line, and when the camera captures another color difference edge line, the nozzle spraying area ends at the other color difference edge line.

[0036] Furthermore, the initial position is the center position of the spraying base in the Z-axis direction.

[0037] Furthermore, the image acquisition unit and the projection unit form a structured light system to obtain depth data of the wall, wherein, before spraying, the projection unit uses a single projection, and the controller extracts the corner position information according to the depth data;

[0038] During spraying, the controller controls the spraying area of ​​the nozzle to stop at the corner position and detects the positive corner and the negative corner of the wall according to the depth data.

[0039] Furthermore, when a positive corner of the wall is detected, the following operations are performed after spraying is completed:

[0040] Let s be the spraying distance from the sprayer to the wall;

[0041] The spraying part returns to the center position on the Z-axis direction of the spraying base; the controller controls the electric wheel to drive the spraying machine to move so that the orthographic projection of the midpoint of the line connecting the two ultrasonic sensors to the wall falls on the corner of the wall, and the depth data at this position is obtained. According to the depth data, the angle θ1 of the positive corner of the wall is obtained;

[0042] At this time, the sprayer continues to move L1 in the predetermined direction from the self-judgment position to the safety position; it continues to move L2 in the predetermined direction from the safety position to the corner position; after the sprayer rotates by an angle θ1, the spraying direction of the sprayer nozzle is perpendicular to the plane of the other wall, and spraying is performed along the other wall at the corner;

[0043] During spraying, the ultrasonic sensor detects the distance from the sprayer to the wall in real time, and the controller controls the electric wheel to correct the direction of the entire sprayer, so that the spraying distance from the sprayer to the wall remains at s;

[0044] Among them, L1 is 1 / 2 of the overall width W of the spraying machine;

[0045] L2=s*tan(135°-θ1), 90°≤θ1<180°;

[0046] When a wall concave corner is detected, perform the following operations after spraying:

[0047] The spraying part returns to the center position in the Z-axis direction on the spraying base, obtains the depth data at this position, and obtains the angle θ2 of the inner corner; the controller controls the electric wheel to drive the sprayer to retreat L3 in the X-axis and Y-axis directions respectively; the rotation angle of the sprayer is β= (180°-θ2), 90°≤θ2<180°, and the spraying direction of the sprayer nozzle is perpendicular to the plane where the other wall is located; in the width direction of the sprayer, the controller controls the electric wheel to drive the sprayer to move L4 in the X-axis direction, so that the positive projection of the midpoint of the line connecting the two ultrasonic sensors to the wall falls on the corner of the wall. This position is recorded as the transfer position, and the sprayer continues to move 1 / 2 of the overall width W of the sprayer in the X-axis direction from the transfer position;

[0048] In the Y-axis direction, the sprayer moves forward so that the spraying distance from the sprayer to the wall is s, and the spraying direction of the sprayer nozzle is perpendicular to the plane of the other wall, and the spraying is performed along the other wall at the corner;

[0049] Among them, L3≥D / 2-W / 2, D is the maximum width dimension on the Z-axis section of the spray machine.

[0050] Furthermore, when the spraying part returns to the center position in the Z-axis direction on the spraying base and the angle of the corner is not detected, the spraying part is controlled to move in the X-axis direction until the corner is detected again and the angle of the corner is calculated.

[0051] Furthermore, a maximum stroke value is set for the translation stroke value of the sprayer, and when the translation trajectory of the sprayer is equal to the maximum stroke value, a prompt message is issued.

[0052] Furthermore, before or during spraying, the image acquisition unit acquires the current wall image, pre-processes the acquired image, and uses the Canny edge detection algorithm to detect the edge in the image to identify the two-dimensional contour of the wall, and obtain the two-dimensional features in the wall, the two-dimensional features including cracks, color difference or flatness;

[0053] Furthermore, the Canny edge detection algorithm is used to detect the edges in the image to identify the two-dimensional contour of the wall, and the two-dimensional features of the wall include:

[0054] After completing Canny edge detection on the acquired image, convert the image from RGB color space to HSV color space and set the threshold, perform threshold segmentation on the image and perform denoising to obtain a color segmented image;

[0055] The gray-level co-occurrence matrix of the color segmented image is calculated and the texture features are extracted to obtain crack, color difference or flatness information.

[0056] Furthermore, before or during spraying, the projection unit projects structured light onto the wall, the image acquisition unit captures the structured light pattern reflected back from the wall, and transmits the image to the controller for processing, and calculates the change of the structured light pattern through triangulation to obtain the depth information of the wall; calculates the normal direction of each area of ​​the wall, and obtains the slope information of the wall based on the normal direction.

[0057] Further, the initial spraying pressure of the sprayer is P0, and the required spraying pressure for the cracked area or uneven area is P;

[0058] P=P0+k p *(Δd)+k pθ *θ

[0059] where k p is the pressure gain coefficient, Δd represents the change in wall depth, a positive value represents a depression, a negative value represents a bulge, and vice versa; k pθ is the spraying pressure slope gain coefficient, θ is the wall slope;

[0060] The initial spraying speed of the sprayer is V0, and the spraying speed for the color difference area is V;

[0061] V=V0+k v *(Δc)+k vθ *θ

[0062] where k v is the speed gain coefficient, Δc represents the degree of wall color difference, k vθ is the spraying speed slope gain coefficient.

[0063] Further, the spraying machine includes a full spraying mode and a single column spraying mode;

[0064] The full spray mode is to control the sprayer to the spraying position, and the nozzle sprays the wall surface corresponding to the spraying position within the entire stroke of the nozzle according to the received instructions;

[0065] The single-row spraying mode is to control the sprayer to be at the spraying position, and the nozzle only moves in the center line direction of the Y-axis and / or Z-axis of the spraying base during spraying according to the received instructions. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Figure 1 A schematic diagram for illustrating the structure of a spray coating machine in an embodiment;

[0067] Figure 2 It is a schematic diagram for explaining the structure of the spraying machine after the spraying base is raised and the secondary frame is slightly raised in the embodiment;

[0068] Figure 3 Schematic diagrams of the structure for explaining that the secondary frame of the spraying machine in the embodiment is raised to a higher position, wherein (a) is a schematic diagram of separating the spraying unit from the secondary frame, and (b) is a schematic diagram of the secondary frame and the primary frame after the spraying unit is removed;

[0069] Figure 4 is a schematic structural diagram for illustrating a spray unit in an embodiment;

[0070] Figure 5 are schematic diagrams for illustrating the structure of the spraying machine in the embodiment from a lateral perspective, wherein (c) is a schematic diagram for illustrating the side view of the spraying machine in the embodiment, and (d) is a schematic diagram for illustrating the front view of the spraying machine in the embodiment;

[0071] Figure 6 is a schematic diagram for explaining the spraying method in the embodiment from spraying a straight wall to spraying a curved wall;

[0072] Figure 7Schematic diagrams for illustrating three types of wall surfaces that the image acquisition unit of the spraying machine mainly faces in the spraying method in the embodiment, wherein (e) is a schematic diagram of a concave situation, (f) is a schematic diagram of a convex situation, and (g) is a schematic diagram of an uneven situation;

[0073] Figure 8 A schematic diagram for explaining the movement and transformation of the spraying machine in the embodiment when targeting a right-angled positive angle;

[0074] Fig. 9 A schematic diagram for explaining that a spraying machine in an embodiment detects wall corner information from a distant view;

[0075] Fig.10 A schematic diagram for explaining the movement and transformation of the spraying machine in the embodiment for an obtuse positive angle;

[0076] Fig.11 A schematic diagram for explaining the movement and transformation of the spraying machine in the embodiment for a right-angle internal corner;

[0077] Fig.12 A schematic diagram for explaining the movement and transformation of the spraying machine in the embodiment when targeting an obtuse internal angle;

[0078] 1-bottom plate; 2-electric wheel; 3-blower; 5-handrail; 6-control panel bracket; 7-control panel; 8-first-level vertical pole; 9-fixed guide rail limit block; 10-motor fixed block; 11-motor A; 12-first-level vertical pole connector; 13-material box; 14-descent limit block; 15-secondary vertical pole; 16-first-level slide rail; 17-slider A; 18-vertical pole transmission gear; 19-secondary auxiliary seat; 20-synchronous wheel fixing frame; 21-motor connecting seat; 22-gear box; 23-motor B; 24-conical spur gear; 25-synchronous wheel; 26-synchronous belt; 27-secondary vertical pole connector; 28-pressing plate A; 29-pressing plate B; 30-pressing plate connecting plate; 31-spraying base; 32-secondary slide rail; 33-secondary limit block; 34-slider B; 35-dust suction 1-1. The nozzle is connected to the nozzle with a screwdriver. 2-2. The nozzle is connected to the nozzle with a screwdriver. 3-3. The nozzle is connected to the nozzle with a screwdriver. 4-4. The nozzle is connected to the nozzle with a screwdriver. 5-6. The nozzle is connected to the nozzle with a screwdriver. 7-8. The nozzle is connected to the nozzle with a screwdriver. 9-10. The nozzle is connected to the nozzle with a screwdriver. 11-22. The nozzle is connected to the nozzle with a screwdriver. 12-33. The nozzle is connected to the nozzle with a screwdriver. 13-44. The nozzle is connected to the nozzle with a screwdriver. 14-5. The nozzle is connected to the nozzle with a screwdriver. 15-6. The nozzle is connected to the nozzle with a screwdriver. 16-7. DETAILED DESCRIPTION

[0079] The technical solutions in the embodiments of the present application are described below in conjunction with the accompanying drawings in the embodiments of the present application. In the embodiments of the present application, words such as "exemplarily" or "for example" are used to indicate examples, illustrations or descriptions.

[0080] In interior decoration projects, wall spraying is a crucial process. Traditional spraying methods mainly rely on manual operation, which has many limitations. Operators need to frequently adjust the direction, angle, distance and other parameters of the handheld spray gun, which places high demands on the operator's skills and experience; manual spraying often leads to uneven or uneven wall coating thickness; in addition, when spraying in a closed indoor environment, the air flow is poor and the concentration of pollutants is high. Long-term exposure to such an environment will have an adverse effect on the health of operators. Moreover, compared with the automated spraying system, manual spraying is less efficient and difficult to meet the needs of large-scale or rapid construction.

[0081] At present, automated and intelligent spraying equipment is designed to solve the current problem of manual spraying. Among them, the automatic spraying machine using a mechanical arm is widely regarded as an effective solution to replace manual spraying due to its highly automated characteristics. However, the purchase and maintenance costs of this type of equipment are relatively high. Although it has good flexibility within a certain range, the mechanical arm is large in size and needs to perform a variety of stretching, bending and shaking movements. In complex and more compact indoor environments, such as corners, corners, and walls with a certain curvature, and in the case of relatively narrow space, its adaptability is still insufficient, which will also lead to its range of motion being limited in indoor environments with limited space, and further reduce its applicability in compact spaces. Therefore, if the current mechanical arm spraying equipment is used in a compact indoor environment, such as a small space residence or apartment, not only the installation cost and transportation cost are high, but also its display space is greatly limited in this environment, and its applicability is not good. In view of this situation, this embodiment provides an automatic spraying machine, which uses an embedded structure of a secondary frame 200 and a primary frame 100 to accurately determine the lifting stroke of the spraying unit in the entire Z-axis direction. This two-stage lifting mechanism greatly expands the spraying range in the height direction, and at the same time places the entire spraying unit on the inner side of the secondary frame 200, and is embedded in the secondary frame 200 through the spraying base 31, ensuring that the travel of the entire spraying unit in the X-axis and Y-axis directions is inside the secondary frame 200. This design not only allows the automatic spraying machine to maintain high flexibility while occupying less space, and is very suitable for indoor environments with relatively compact space, but also the design of this two-stage lifting frame is more concise, intuitive, and square than the traditional robotic arm automatic spraying equipment, which helps to improve the stability and accuracy of the spraying process. The above-mentioned proposed scheme is elaborated in detail below through the description of multiple embodiments.

[0082] Embodiment 1:

[0083] Reference Figures 1 to 5 , an automatic spraying machine, comprising a spraying unit, a secondary frame 200 and a primary frame 100; the spraying unit is used to spray the wall; the spraying unit is arranged inside the frame of the secondary frame 200, and the frame of the secondary frame 200 is provided with a secondary lifting mechanism that enables the spraying unit to be lifted and lowered along the Z-axis direction of the secondary frame 200; the secondary frame 200 is arranged inside the frame of the primary frame 100, and the frame of the primary frame 100 is provided with a primary lifting mechanism that enables the secondary frame 200 to be lifted and lowered along the Z-axis direction of the primary frame 100;

[0084] The spraying unit includes a spraying base 31 which is transmission-connected to the secondary frame 200 through a secondary lifting mechanism and a spraying part which can be movably arranged on the spraying base 31 along the X and Y axes for spraying the wall. The positive projection of the movable trajectory of the connection between the spraying part and the spraying base 31 is located at least inside the frame of the secondary frame 200.

[0085] In view of the problem that the space required for the robot arm movement trajectory in the existing robot arm spraying equipment is large, this automatic spraying machine adopts a design in which the secondary frame 200 and the primary frame 100 are embedded. By constraining the lifting stroke of the entire frame in the Z-axis direction, the lifting stroke of the spraying unit in the entire Z-axis direction is determined. This two-stage lifting method significantly improves the spraying range in the height direction. In addition, the entire spraying unit is arranged on the inner side of the secondary frame 200 and the stroke of the spraying part in the X-axis and Y-axis directions is limited by the spraying base 31, ensuring that the spraying unit runs inside the secondary frame 200. Compared with traditional robot arm automatic spraying equipment, this design reduces the occupied space while maintaining high flexibility, making it more suitable for indoor environments with relatively compact space. In addition, the design of this two-stage lifting frame is more concise, intuitive and square than the robot arm spraying equipment, which helps to ensure stability and accuracy during the spraying process.

[0086] This automatic spraying machine ensures a constant distance and parallel state between the nozzle 40 and the wall during the spraying process through the embedded secondary frame 200 structure. This design limits the range of motion of the spraying unit in the Z-axis direction, allowing the spraying machine to achieve more efficient spraying operations in a smaller space. At the same time, by arranging the spraying unit on the inside of the secondary frame 200, the range of motion of the spraying unit in the X-axis and Y-axis directions is further optimized, ensuring that the spraying unit can complete the required spraying tasks within the limited space. In addition, this simple and intuitive design also helps to simplify the maintenance and debugging process of the equipment, improves the overall reliability and ease of use of the equipment, and is conducive to achieving high-quality spraying effects in a compact space environment.

[0087] The above embodiment can be further optimized, such as the secondary rack 200 includes: a secondary frame, a secondary slide rail, and a secondary driving mechanism.

[0088] The secondary frame is connected to the primary frame 100 through a primary lifting mechanism, so that the secondary frame can be lifted and lowered along the Z-axis direction of the primary frame 100; the secondary slide rail is arranged on the secondary frame and along the Z-axis direction; the secondary driving mechanism is arranged on the secondary frame, and the secondary driving mechanism is connected to the spray base 31, so as to drive the spray base 31 to perform lifting and lowering movements along the Z-axis direction.

[0089] A secondary slide rail is provided here, which can accurately control the lifting and lowering movement of the spray base 31, ensuring the precise movement of the spray unit in the vertical direction (Z axis), while helping to reduce the shaking of the spray unit during the lifting process and improving the stability of the spraying process. This ensures that the distance between the spray unit and the wall remains consistent during the spraying process, thereby ensuring the spraying quality.

[0090] The secondary frame includes secondary uprights 15 and secondary upright connectors 27; the secondary uprights 15 are arranged along the Z-axis direction, and the secondary slide rails are set on the secondary uprights 15; the top ends of multiple secondary uprights 15 are connected by the secondary upright connectors 27, so that the secondary frame forms a frame structure supported by multiple secondary uprights 15.

[0091] The design of the secondary pole 15 and the secondary pole connector 27 simplifies the overall structure of the secondary frame, reduces the complexity of the equipment, and reduces manufacturing and maintenance costs. The design of the secondary pole 15 allows the spray unit to be flexibly adjusted according to the height of the wall, and can better adapt to various wall heights.

[0092] The first-level frame 100 includes a base plate 1 and a first-level upright pole 8; the bottom of the base plate 1 is supported by an electric wheel 2; the first-level upright pole 8 is arranged above the base plate 1 along the Z-axis direction, and the first-level upright pole 8 is connected to the second-level frame through a first-level lifting mechanism, which is used to drive the second-level frame to perform lifting actions along the Z-axis direction.

[0093] The space occupied by the primary rack 100 is determined by the bottom plate or the primary pole 8. Figure 1 The space occupied by the first-level rack 100 in the horizontal direction is determined by the base plate 1.

[0094] The specific configuration of the first-level lifting mechanism to realize the lifting of the second-level frame 200 can be set according to the following scheme. The entire second-level frame 200 and the first-level frame 100 can be configured with multiple rod groups and multiple lifting motors. The above-mentioned first-level pole 8 forms a first-level pole group, and the second-level pole 15 forms a second-level pole group. The first-level pole group and the second-level pole group are four parallel hollow support rods. The first-level pole 8 is provided with a first-level slide rail 16 parallel to it. The lower end of the first-level pole group is fixed on the bottom plate 1, and the upper end of the first-level pole group is provided with a fixed guide rail limiting block 9 and a motor fixing block 10. The function of the limiting block is to determine the lowest extension and lowering position of the second-level pole group, and the function of the motor fixing block 10 is to fix the motor A11 that controls the lifting and lowering of the second-level pole 15. Two first-level pole connectors 12 are provided in the middle of the first-level pole group to connect the two support rods on the left and right sides. A descending limiting block is provided on the lower end of the pole group near the spray base 31, and its function is to determine the lowest descending position of the spray base 31. The lower part of the secondary pole group is provided with a plurality of small bolt holes for connecting the two movable slide blocks A17 on the primary slide rail 16. The starting motor A11 transmits the torque to the pole transmission gear 18 connected to the motor, and the pole transmission gear 18 drives the long tooth block fixed on one side surface of the secondary pole group to move, thereby realizing the lifting and self-locking of the secondary pole group.

[0095] The secondary rod group is welded with a secondary auxiliary seat 19 at both the upper and lower ends. The upper surface of the secondary auxiliary seat 19 is provided with a lower synchronous wheel fixing frame 20 and a motor connecting seat 21. The motor connecting seat 21 is provided with a gear box 22 and a motor B23. The connecting shaft of the motor B23 passes through the gear box 22 and is connected to the conical spur gear 24 inside the box. The connecting shaft of the synchronous wheel 25 passes through the gear box 22 and is connected to another conical spur gear 24 inside the box. The two conical spur gears 24 are meshed. An upper synchronous wheel fixing frame 20 and a synchronous wheel 25 are provided below the upper auxiliary seat. The synchronous belt 26 passes around the upper and lower synchronous wheels 25. The surface of the wheel and the belt has racks of the same size. The meshing of the racks increases the stability of the transmission. The upper surface is connected to the secondary pole connecting piece 27 of the secondary pole 15. The connecting piece here is to increase the stability of the secondary rod group.

[0096] The four synchronous belts 26 are provided with a pressing plate A28 and a pressing plate B29. The pressing plate B29 is fixed on the synchronous belt 26. The pressing plate A28 is fixed on both ends of the pressing plate connecting plate 30. The pressing plate connecting plate 30 is connected to the spray base 31 through the upper platform on the spray base 31. The two pressing plates press the synchronous belt 26, so that the spray base 31 and the synchronous belt 26 can be lifted and lowered synchronously. A secondary slide rail 32 is provided on the inner side of the secondary lifting column. A secondary limit block 33 is provided on the upper end of the secondary slide rail 32. The secondary slide rail 32 is connected to the pressing plate connecting plate 30 through a slider B34. The secondary limit block 33 is used to specify the highest lifting position of the spray base 31. The lifting device first raises the spray device to a certain height through the synchronous belt 26 and the secondary slide rail 32, and then adjusts the height during spraying through the primary slide rail 16 to achieve wall spraying at multiple heights.

[0097] A blower 3 is provided on the upper front side of the bottom plate 1, and an electrical box 4 and a handrail 5 are provided on the upper rear side. The electrical box 4 is used to store power distribution to protect the normal operation of electrical equipment and the safety of maintenance personnel. A control panel bracket 6 is fixedly connected to the upper corners of the two parallel handrails 5, and a rectangular control panel 7 with a 60% tilt is provided thereon. The control panel 7 is bolted to the control panel bracket 6, with a suitable height and easy operation.

[0098] Embodiment 2:

[0099] Combination Figures 1 to 5 The spraying part includes a spray head 40 and a spray machine frame; the spray head 40 is used to spray the wall; the spray machine frame is arranged on the spray base 31, and the spray head 40 is arranged on the spray machine frame, and the spray machine frame is used to drive the spray head 40 to move selectively along the X-axis or / and the Y-axis; here, a screw rod and a slide table can be used to form a mechanism for moving the spray head 40 along the X-axis or / and the Y-axis.

[0100] Among them, an image acquisition unit is provided on the nozzle 40 and is arranged parallel to the direction of the nozzle 40. The image acquisition unit is used to collect image data of the corresponding area of ​​the nozzle 40; a projection unit 50 is provided on the spraying machine frame or the spraying base 31. The projection unit 50 can be arranged on the spraying base with an adjustable angle to adjust the direction of the projection unit 50, so as to facilitate the image acquisition unit to accurately calculate the three-dimensional information quality of the surface of the object using the triangulation principle.

[0101] In the horizontal direction perpendicular to the spraying of the nozzle 40 or the horizontal direction perpendicular to the direction of the lens of the image acquisition unit, an ultrasonic sensor 67 is respectively arranged on both sides of the nozzle 40, and the nozzle 40 is located at the midpoint of the line between the two ultrasonic sensors 67, and the ultrasonic sensor 67 is used to obtain the distance data from the area in front of the nozzle 40 to the ultrasonic sensor 67;

[0102] The automatic spraying machine for indoor decoration walls also includes a controller for controlling the nozzle 40 and the spraying machine frame. The controller is respectively connected to the electric wheel 2 and the ultrasonic sensor 67 for controlling the electric wheel 2 to drive the automatic spraying machine for indoor decoration walls to perform a specified translation according to the distance data. The specified translation is a tangent translation from the midpoint of the line connecting the two ultrasonic sensors 67 to the wall point where the orthographic projection of the wall is located. The controller is also respectively connected to the image acquisition unit and the projection unit 50 for controlling the projection of the projection unit 50 onto the wall and controlling the image acquisition unit to obtain image data on the wall. The above-mentioned controller is also connected to the primary and secondary lifting mechanisms at the same time to control the lifting action of the entire spraying machine.

[0103] On the basis of the sprayer of the above-mentioned embodiment 1, thanks to the two-stage lifting and two frame structures forming an overall structure, the structure provides a stable and reliable working frame environment for the image acquisition unit and the projection unit 50, which can realize the division of the entire wall (whether it is a straight wall or a curved wall) into multiple more reliable and clear vertical column areas, so that it is possible to provide the image acquisition unit and the projection unit 50 with multiple clear and definite spraying positions. Each time spraying is performed, image acquisition and projection operations can be performed in the vertical column area of ​​the wall corresponding to the clear and definite spraying position, thereby ensuring the image acquisition quality and the spraying quality achieved according to the image acquisition quality.

[0104] Specifically, the image acquisition unit of the above scheme can capture the wall image in real time, help identify the wall features (such as cracks, color difference, etc.), and adjust the spraying parameters according to these features, so as to improve the spraying quality. The projection unit 50 can be used in combination with the image acquisition unit to form a structured light system to obtain the depth data of the wall, and obtain the distance data from the area in front of the nozzle 40 to the ultrasonic sensor 67 through the ultrasonic sensor 67. The controller can automatically adjust the position of the sprayer according to these data to ensure that the nozzle 40 maintains a constant distance from the wall. In this way, by setting the projection unit 50, the image acquisition unit, the ultrasonic sensor 67, and the controller, a system for acquiring the wall image features and depth information and controlling the entire sprayer according to this information is formed. Such intelligent control not only helps to improve the flatness and uniformity of the spraying, but also provides a hardware basis for controlling the electric wheel 2 to perform a specified action through the controller. Such a system can automatically adjust the position without occupying extra space in conjunction with the overall compact frame of the sprayer to adapt to special structures such as corners and curved walls. The automatic spraying method for indoor decoration walls mentioned below will be further explained.

[0105] The nozzle 40 includes a nozzle fixing frame 61 and a nozzle 64; the nozzle fixing frame 61 is rotatably arranged on the spray machine frame, so that the nozzle fixing frame 61 can rotate around the X-axis or the Y-axis; the nozzle 64 is arranged on the nozzle fixing frame 61, and is used to spray the wall; the image acquisition unit is arranged on the upper side of the nozzle fixing frame 61 and corresponds to the nozzle 64 on the nozzle fixing frame 61 up and down; at least two ultrasonic sensors 67 are respectively arranged on both sides of the nozzle fixing frame 61; the direction of the ultrasonic sensor 67, the direction of the nozzle 40, and the direction of the image acquisition unit are all arranged in parallel.

[0106] The secondary frame 200 and the primary frame 100 are both rectangular prism frames; the nozzle 40 is oriented perpendicular to the plane where one side of the primary frame 100 is located. The cross-sections of the secondary frame 200 and the primary frame 100 in the Z-axis direction are square; the side of the secondary frame 200 is parallel to the side of the primary frame 100.

[0107] Through the real-time feedback of the image acquisition unit, the position and spraying direction of the nozzle 40 can be accurately controlled to ensure uniform spraying. The at least two ultrasonic sensors 67 are respectively arranged on both sides of the nozzle fixing frame 61, which can not only monitor the distance data from the front area of ​​the nozzle 40 to the ultrasonic sensor 67 in real time to ensure that the nozzle 40 maintains a constant distance from the wall, but also to enable the first-stage frame 100 or the entire spraying machine to maintain a parallel state with the wall when the distance data obtained by the at least two ultrasonic sensors 67 are obtained in real time, so that the wall facing the nozzle 40 is always facing the wall when the entire spraying machine is in each spraying position.

[0108] In other words, according to the wall shape of the current common residential interior design, at least two ultrasonic sensors 67 are arranged, so that on the planned path of the entire sprayer translation, the spraying surface of the first-stage frame 100 or the entire sprayer can always be a cross-section of the corresponding wall. This can greatly reduce the complexity of the wall facing the spraying unit. For example, when the wall has a curved surface or a certain curvature, during the spraying process, the sprayer direction is adjusted according to the data detected by the ultrasonic sensor 67. Figure 7 Even when facing a wall with a certain curvature or curve, the nozzle 40 relies on the machine vision to adjust the spraying parameters accordingly only to control the inner concave, outer convex and uneven (i.e., multiple uneven walls), which simplifies the wall conditions to be sprayed.

[0109] By adopting this scheme, a parallel line path planning scheme formed by setting at least two ultrasonic sensors 67 (the line between at least two ultrasonic sensors 67 is always parallel to the section where the corresponding wall intersection point is located) is simpler than the more complex path planning algorithm (RRT path planning algorithm, APF artificial potential field method path planning algorithm, etc.) adopted by the robotic arm automatic spraying equipment. It only needs to control the difference between the two ultrasonic sensors 67 to be kept within the preset range, and control the direction of the entire sprayer to ensure that the distance between the entire sprayer and the wall is not only within the specified range, but also the entire sprayer can be kept facing the wall in the translation path. This not only makes program debugging simpler and maintenance more convenient, but also greatly improves the reliability and maintenance convenience of software and hardware.

[0110] A material box 13 is arranged in the spray base 31, and a nozzle 40 is connected to the material box 13, and is used to spray the spray material in the material box 13 from the nozzle 40; when specifically arranged, the material box 13 can be centered, and an upper platform and a lower platform are respectively arranged on the upper and lower sides of the material box 13 to clamp it to form the spray base 31. A dust suction assembly is also arranged on the primary frame 100, and the dust suction assembly includes a dust suction part 35 and an air pump connected to the air outlet of the dust suction machine; the dust suction part 35 is arranged at the lower end of the spray base 31, and the air inlet of the dust suction part 35 is oriented in the same direction as the spraying direction; the air outlet of the air pump is connected to the material box 13 through an air filter device.

[0111] During the specific configuration, a dust suction pipe fixing part 36 is welded under the spray base 31, and a dust suction part 35 is welded on the dust suction pipe fixing part 36. The mouth end of the dust suction part 35 is fixedly connected to a stretchable air pump pipe A37 through a fixing part. The blower 3 is arranged on the bottom plate 1, and an air filter 38 is arranged at the gas inlet end, and the gas outlet end is fixedly connected to another stretchable air pump pipe B39, and the upper end opening of the pipe is connected to the spray main frame. One end of the feed pipe 41 extends into the inside of the material box 13, and the position of the end is fixed by the material pipe fixing part on the material box 13, and the other end is connected to the feed port on the feeder. The working principle of the feed mechanism adopted by this spray unit is the Bernoulli principle. After the air pump is turned on and used, the pressure at the upper end connection of the air pump pipe is large, and the pressure at the feed port is small. The air flow rate inside the spray main frame is fast. Under the action of the air pressure difference, the paint will continue to enter the inside of the spray main frame through the feed pipe 41, and be sprayed out from the nozzle 64 through the atomizing cap.

[0112] The material box 13 is fixed with a slide rail support platform 42 at both ends of the upper side, a nozzle slide rail 43 is provided on the upper surface of the support platform, and slide rail limit blocks 44 are fixed at the front and rear ends. Slide blocks C45 are provided on both nozzle slide rails 43, and the slide blocks C45 are fixedly connected to the left and right sides of the slide 46. A motor C47 is fixed to the middle of the front end of the material box 13, and a screw fixing part 48 is fixed to the rear end. One end of the screw 49 passes through the screw transmission part on the lower side of the slide 46 and is connected to the motor C47, and the other end is connected to the screw fixing part 48. The motor drives the screw 49 to rotate, and then the screw 49 drives the spraying equipment to move forward and backward. The nozzle slide rail 43 is used to ensure the stability and parallelism of the moving trajectory of the spraying equipment.

[0113] The left and right ends of the slide 46 are fixedly connected to the sliding shaft 52 through the connecting plate 51, the sliding shaft is connected to the shaft wrapper 53, the shaft wrapper 53 is fixedly connected to the worm fixing part, the upper end of the worm fixing part is open, and a short worm is arranged inside, one end of the motor bracket D55 is fixed to the lower side of the worm fixing part, the motor D56 is fixed to the motor bracket D55, one end of the shaft connecting part is connected to the worm through a key, the worm is meshed with the slide gear in the middle of the shaft wrapper 53, and the slide gear is meshed with the slide 46 rack on the sliding shaft. The motor transmits torque through the shaft, which successively drives the rotation of the worm, the gear and the movement of the shaft wrapper 53 to realize the left and right movement of the spraying device.

[0114] The lower ends of the two support plates 57 are fixed to the worm fixing member, and the motor E59 is fixed to the support plate 57 on one side of the upper end through the shaft and the cover shaft member, and is rotatably connected to the nozzle connecting plate 60. The support plate 57 on the other side is rotatably connected to another nozzle connecting plate 60 through the shaft, and the nozzle fixing frame 61 is welded to the upper end of the nozzle connecting plate 60. The motor E59 is used to control the tilt angle of the nozzle 40 during spraying.

[0115] The nozzle 40 adopts the principle of an air spray gun, which is fixed inside the nozzle fixing frame 61. The lower end of the fixing frame is provided with two openings. The motor F62 that controls the spraying passage passes through one opening and is connected to the switch rotating rod 63 through the shaft and the cover shaft. The material pipe passes through the other opening and is connected to the material passer. An opening is provided at the front end of the fixing frame, and the nozzle 64 extends out of the front opening. A camera protective shell 65 is fixed at the upper end of the fixing frame. An image acquisition unit for monitoring the spraying status and collecting wall images is provided inside the protective shell. The image acquisition unit can be a camera 66. The two ultrasonic sensors 67 mentioned above for monitoring the spraying distance are provided on the left and right sides of the fixing frame. The interactive device of the above-mentioned controller, i.e., the control panel, can be provided on the handle arranged at the rear side of the sprayer.

[0116] Embodiment three:

[0117] Reference Figure 4 and Figure 5 The nozzle 40 is connected to the spray machine frame through a pitch rotation mechanism, which is used to allow the nozzle 40 to rotate around the X-axis direction (the width direction of the spray machine). The pitch rotation angle of the nozzle 40 is -30°~90°. In this way, a certain pitch rotation can be achieved, and in particular, the nozzle 40 can be pitch-adjusted, which is convenient for spraying operations in complex locations such as horizontal corners and top ceilings. The nozzle 40 is a single-mouth wide-angle spray nozzle (about 130-160° or 150° wide angle). This improves the uniformity of the spraying and avoids the spraying interference phenomenon (similar to the ripple superposition effect) caused by the one-way multi-nozzle design of the current spraying equipment.

[0118] The spraying position of the nozzle 40 of the spray machine is controlled by three motors. One motor controls the screw 49 to move the nozzle 40 forward and backward, one motor controls the shaft wrapper 53 to move along the sliding axis to move the nozzle 40 left and right, and the last motor controls the rotation of the nozzle 40. The forward and backward movement, left and right movement and rotation of the nozzle 40 work together to effectively realize the spraying of the nozzle 40 at different angles in various positions. The spraying process has a very high degree of automation, which greatly increases the continuity of the spraying operation and improves work efficiency.

[0119] Embodiment 4:

[0120] Combination Figures 6 to 12 , an automatic spraying method for indoor decoration wall based on machine vision, using the automatic spraying machine for indoor decoration wall of any solution of the above-mentioned embodiment 1 to embodiment 3 to spray the wall surface of wall 300, the automatic spraying method for indoor decoration wall includes the following operations:

[0121] A coordinate system is established with the center of the spraying machine, the width direction of the spraying machine is the X-axis direction, the forward spraying direction of the spraying machine is the Y-axis direction, and the height direction of the spraying machine is the Z-axis direction;

[0122] Move the indoor decoration wall automatic spraying machine to the wall to be sprayed, so that the spraying part faces the wall to be sprayed;

[0123] An image acquisition unit is used to capture a wall image, and a controller is used to extract specified features in the wall image, and coordinate data of the specified features are calculated; the specified features include cracks, color difference blocks, and color difference edges;

[0124] The ultrasonic sensor 67 is used to obtain the distances Y1 and Y2 between the two ultrasonic sensors 67 and the wall respectively, and a change angle threshold ΔY is set;

[0125] When |Y1-Y2|≤ΔY, the spraying operation is performed, and after the spraying is completed, the automatic spraying machine for indoor decoration walls is moved to the next spraying position according to the extracted color difference edge line;

[0126] When |Y1-Y2|>ΔY, the controller controls the electric wheel 2 to drive the automatic sprayer for interior decoration walls to rotate around the Z axis, so that |Y1-Y2|≤ΔY, and then the spraying operation is performed. After the spraying is completed, the automatic sprayer for interior decoration walls is moved to the next spraying position according to the extracted color difference edge line.

[0127] The automatic spraying method for indoor wall decoration adopts a special and concise path planning method in the design scheme. Only the distance data obtained by the ultrasonic sensor 67 for detecting the spraying distance can be used to perform concise path planning and direction control of the entire spraying machine. Figure 6 and Figure 7, the M area in the figure is the image range captured by the camera, and the P area is the range sprayed by the nozzle 40. In the scheme, at least two ultrasonic sensors 67 are arranged on both sides of the nozzle fixing frame 61, and their main function is to monitor the distance data between the front area of ​​the nozzle 40 and the ultrasonic sensor 67 in real time. These data are not only used to maintain a constant distance between the nozzle 40 and the wall, but also to ensure that the spraying surface of the first-stage frame 100 or the entire sprayer is always parallel to the wall by obtaining the distance information measured by at least two ultrasonic sensors 67 in real time. This arrangement ensures that on the translation path of the entire sprayer, the spraying surface of the first-stage frame 100 or the entire sprayer (the side facing the wall) can be used as a section of the corresponding wall or a parallel surface to the section, thereby significantly reducing the complexity of the wall faced by the image acquisition unit during the spraying process, thereby reducing the complexity of the parameters required to be called during spraying.

[0128] like Figure 6 and Figure 7 In this way, even when facing a wall with a certain curvature or non-planar characteristics, the sprayer can adjust its direction according to the data detected by the ultrasonic sensor 67, and then only needs to adjust the spraying parameters according to the concave, convex and uneven characteristics of the wall, which simplifies the wall conditions that need to be processed during the spraying process, such as Figure 7 . Compared with the complex path planning algorithm used in traditional robotic arm automatic spraying equipment, the parallel line path planning scheme based on at least two ultrasonic sensors 67 proposed in this scheme is simpler and more effective. It is only necessary to ensure that the distance difference between the two ultrasonic sensors 67 is within a predetermined range to effectively control the direction of the entire sprayer, ensure that the sprayer and the wall always maintain a constant and appropriate distance, and ensure that the sprayer faces the wall on the translation path. This method not only simplifies the program debugging process, improves the reliability and maintainability of the software and hardware systems, but also ensures the quality and efficiency of spraying.

[0129] Before spraying, the connection between the spraying part and the spraying base 31 moves to the initial position, and the initial position meets the conditions:

[0130] The distance from the connection to the plane (a plane perpendicular to the horizontal plane) in the Z-axis direction where the edge of the spraying base 31 close to the wall is located is greater than 0; when spraying, the nozzle 40 starts spraying from the side of the spraying base 31 close to the color difference edge line, and when the camera captures another color difference edge line, the spraying area of ​​the nozzle 40 ends at the other color difference edge line. The initial position is the center position on the spraying base 31 in the Z-axis direction.

[0131] Such a design allows the nozzle 40 to be based on the structured light system formed by the image acquisition unit and the projection unit 50. It can not only adjust the spraying parameters according to the wall features and details obtained by the image acquisition unit, but also obtain the point cloud data of the wall according to the wall depth data obtained by the structured light system, reconstruct the three-dimensional contour of the wall from the point cloud data, and then realize wall contour tracking spraying through the spray rack. When the nozzle 40 is spraying, the nozzle 40 will not occupy excess space.

[0132] The image acquisition unit and the projection unit 50 form a structured light system to obtain the depth data of the wall; wherein, before spraying, the projection unit 50 adopts a single projection, and the controller extracts the corner position information according to the depth data; during spraying, the corner position information is extracted according to the acquired wall depth data, and the controller controls the spraying area of ​​the nozzle 40 to stop at the corner position and detects the positive corner and negative corner of the wall according to the depth data. Single projection is adopted here, that is, in order to prevent the image acquisition unit from being interfered by the pattern projected by the projection unit 50 during spraying, when the sprayer reaches the spraying position, a pattern projection is completed, and after the image acquisition unit acquires the projected pattern, the controller calculates the depth data of the wall under the spraying position according to the shape of the image presented on the wall, and then the wall can be sprayed according to the depth data, and the image acquisition unit will not be interfered by the projection pattern when acquiring the detailed features of the wall during spraying.

[0133] In this solution, the structured light system only processes the wall area under the current spraying position, and the trajectory planning of the sprayer is carried out by tracking and translating the wall according to its contour while controlling the direction of the sprayer by the distance detected by the two ultrasonic sensors 67 mentioned above. Compared with the method of directly using structured light technology to perform three-dimensional reconstruction of the entire wall, this solution separates the trajectory planning and the three-dimensional reconstruction of the current wall spraying area, so that the calling parameters of the sprayer during spraying are more concise and clear, and it is also convenient for the maintenance of the entire sprayer.

[0134] Embodiment five:

[0135] Combination Figures 8 to 10 On the basis of the above-mentioned fourth embodiment, when a positive corner of a wall is detected, after spraying is completed, the following operations are performed:

[0136] Let s be the spraying distance from the sprayer to the wall;

[0137] The spraying part returns to the center position on the Z-axis direction of the spraying base 31; the controller controls the electric wheel 2 to drive the spraying machine to move to a position where the orthographic projection of the midpoint of the line connecting the two ultrasonic sensors 67 to the wall falls on the corner of the wall, and obtains the depth data at this position. According to the depth data, the angle θ1 of the positive corner of the wall is obtained;

[0138] At this time, the sprayer continues to move L1 in the predetermined direction from the self-judgment position to the safety position; continues to move L2 in the predetermined direction from the safety position to the corner position; after the sprayer rotates by an angle θ1, the spraying direction of the sprayer nozzle 40 is perpendicular to the plane of the other wall, and spraying is performed along the other wall at the corner;

[0139] During spraying, the distance from the sprayer to the wall is detected in real time by the ultrasonic sensor 67, and the direction of the entire sprayer is corrected by the controller to control the electric wheel 2 so that the spraying distance from the sprayer to the wall is maintained at s;

[0140] Among them, L1 is 1 / 2 of the overall width W of the spraying machine;

[0141] L2=s*tan(135°-θ1), 90°≤θ1<180°;

[0142] Combination Figure 11 to Figure 12 When a wall concave corner is detected, perform the following operations after spraying:

[0143] The spraying part returns to the center position in the Z-axis direction on the spraying base 31, obtains the depth data at this position, and obtains the angle θ2 of the inner corner; the controller controls the electric wheel 2 to drive the sprayer to retreat L3 in the X-axis and Y-axis directions respectively; the rotation angle of the sprayer is β=(180°-θ2), 90°≤θ2<180°, and the spraying direction of the sprayer nozzle 40 is perpendicular to the plane where the other wall is located; in the width direction of the sprayer, the controller controls the electric wheel 2 to drive the sprayer to move L4 in the X-axis direction, so that the positive projection of the midpoint of the line connecting the two ultrasonic sensors 67 to the wall falls on the corner of the wall, and this position is recorded as the transfer position, and the sprayer continues to move 1 / 2 of the overall width W of the sprayer in the X-axis direction from the transfer position;

[0144] In the Y-axis direction, the sprayer moves forward so that the spraying distance from the sprayer to the wall is s, and the spraying direction of the sprayer nozzle 40 is perpendicular to the plane of the other wall, and the spraying is performed along the other wall at the corner; wherein, L3 ≥ D / 2-W / 2, and D is the maximum width dimension on the Z-axis section of the sprayer. In this embodiment, that is, the sprayer is a vertical square structure, and the maximum width dimension on the Z-axis section is the diagonal dimension on the section. The above-mentioned established direction is to continue along the direction of the extended surface of the wall that has been sprayed. The above-mentioned detection is to detect the corner of the wall during the spraying process, such as Fig. 9 During spraying, even the corners in the distance will be captured, and the above operations will be performed after the corner edges are identified.

[0145] This design can be appropriately adjusted according to different types of corners (external corners or internal corners), so as to cope with different wall structures. After obtaining the angle data of the corner and adjusting the spraying direction of the sprayer, according to setting or limiting the above-mentioned values ​​(such as L1, L2, L3 and L4, etc.), when encountering a corner, it can ensure that the sprayer can effectively and cleverly realize the corner turning, so as to smoothly move to the next spraying position to spray the wall on the other side of the corner, and avoid interference with the wall. The spraying position here is the position where the sprayer starts the spraying operation after stopping the translation. The displacement distance between each spraying position can be determined according to the color difference edge line recognized by machine vision, or according to the travel range of the X-axis of the nozzle 40, that is, the travel range of the X-axis of the nozzle 40 is used as a unit, and the width of the entire wall is divided into multiple spraying positions, and a certain interval margin is set.

[0146] When the spraying part returns to the center position in the Z-axis direction on the spraying base and the angle of the corner is not detected, the spraying part is controlled to move in the X-axis direction until the corner is detected again and the angle of the corner is calculated.

[0147] Before or during spraying, the image acquisition unit acquires the current wall image, pre-processes the acquired image, and uses the Canny edge detection algorithm to detect the edges in the image to identify the two-dimensional contour of the wall and obtain the two-dimensional features in the wall, which include cracks, color difference or flatness.

[0148] The Canny edge detection algorithm is used to detect the edges in the image to identify the two-dimensional contour of the wall. The two-dimensional features of the wall include:

[0149] After completing Canny edge detection on the acquired image, the image is converted from RGB color space to HSV color space and a threshold is set. The image is threshold segmented and denoised to obtain a color segmented image. The grayscale co-occurrence matrix of the color segmented image is calculated, and texture features are extracted to obtain crack, color difference or flatness information.

[0150] A maximum stroke value is set for the translation stroke value of the sprayer, and a prompt message is issued when the translation trajectory of the sprayer is equal to the maximum stroke value. Before or during spraying, the projection unit 50 projects structured light onto the wall, and the image acquisition unit captures the structured light pattern reflected back from the wall, and transmits the image to the controller for processing, and calculates the change of the structured light pattern through triangulation to obtain the depth information of the wall; calculates the normal direction of each area of ​​the wall, and calculates the slope information of the wall based on the normal direction.

[0151] Specifically, the initial spraying pressure of the sprayer is P0, and the spraying pressure required for the cracked area or uneven area is P;

[0152] P=P0+kp *(Δd)+k pθ *θ

[0153] where k p is the pressure gain coefficient, Δd represents the change in wall depth, a positive value represents a depression, a negative value represents a bulge, and vice versa; k pθ is the spraying pressure slope gain coefficient, θ is the wall slope; the initial spraying movement speed of the sprayer is V0, and the spraying movement speed for the color difference area is V;

[0154] V=V0+k v *(Δc)+k vθ *θ

[0155] where k v is the speed gain coefficient, Δc represents the degree of wall color difference, k vθ is the spraying speed slope gain coefficient.

[0156] The above pressure gain coefficient (k p and k pθ ) is adjusted according to the following principle: For the wall part closer to the nozzle 40, the spraying pressure needs to be slightly reduced to avoid excessive accumulation of paint. For the wall part farther from the nozzle 40, the spraying pressure needs to be slightly increased to ensure that the paint can be fully covered. v and k vθ ) shall be adjusted according to the following principles:

[0157] The spraying speed is slowed down in areas that need more paint, thereby increasing the amount of paint per unit area and avoiding paint accumulation: for the wall part closer to the nozzle 40, the spraying speed is increased to reduce the amount of paint per unit area and avoid excessive paint accumulation; for areas with relatively flat walls or small color differences, the spraying speed is increased to improve the spraying efficiency without affecting the spraying quality.

[0158] The sprayer includes a full spray mode and a single-row spray mode; the full spray mode is to control the sprayer to be in the spraying position, and the nozzle 40 sprays the wall surface corresponding to the spraying position within the entire stroke of the nozzle 40 according to the received instructions; the single-row spray mode is to control the sprayer to be in the spraying position, and the nozzle 40 only moves in the center line direction of the Y axis or / and Z axis of the spray base 31 during spraying according to the received instructions.

[0159] After reaching the spraying position, in the full spraying mode, the nozzle 40 will spray the wall area under the spraying position within its entire range of motion. This is most suitable for straight walls or slightly curved walls. Under the premise of ensuring spraying efficiency, the spraying uniformity and quality can be well guaranteed by adjusting the spraying parameters through machine vision. In the single-column spraying mode, it is more suitable for walls with large curvature, many curves, and complex curves. When controlling the spraying processing speed, for complex curved walls and walls with many curves, the spraying range is reduced, and the spraying parameters are more finely controlled in the single-column range in the middle of the wall area corresponding to the spraying position, so as to further reduce the complexity of the wall processing required and ensure the uniformity and quality of spraying.

[0160] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. Indoor decoration wall automatic spraying machine, characterized by: include: A spraying unit, used for spraying the wall surface; A secondary frame, wherein the spraying unit is arranged inside the frame of the secondary frame, and a secondary lifting mechanism is arranged inside the frame of the secondary frame so that the spraying unit can be lifted and lowered along the Z-axis direction of the secondary frame; A primary frame, wherein the secondary frame is arranged inside the frame of the primary frame, and a primary lifting mechanism is arranged inside the frame of the primary frame so that the secondary frame can be lifted and lowered along the Z-axis direction of the primary frame; The spraying unit comprises a spraying base which is connected to the secondary frame through a secondary lifting mechanism and a spraying part which can be movably arranged on the spraying base along the X and Y axes for spraying the wall surface, and the orthographic projection of the moving track of the connection between the spraying part and the spraying base is located inside the frame of the secondary frame; The spraying part includes a spray head, which is used to spray the wall surface; The nozzle is provided with an image acquisition unit arranged parallel to the nozzle direction, and the image acquisition unit is used to acquire image data of the area corresponding to the nozzle; A coordinate system is established with the center of the spraying machine, wherein the width direction of the spraying machine is the X-axis direction, the forward spraying direction of the spraying machine is the Y-axis direction, and the height direction of the spraying machine is the Z-axis direction; Move the indoor decoration wall automatic spraying machine to the wall to be sprayed, so that the spraying part faces the wall to be sprayed; Using an image acquisition unit to capture a wall image, extracting specified features in the wall image through a controller, and calculating coordinate data of the specified features; the specified features include cracks, color difference blocks, and color difference edges; In the horizontal direction perpendicular to the spraying of the nozzle or the horizontal direction perpendicular to the direction of the lens of the image acquisition unit, an ultrasonic sensor is respectively arranged on both sides of the nozzle and the nozzle is located at the midpoint of the line between the two ultrasonic sensors, and the ultrasonic sensor is used to obtain the distance data from the area in front of the nozzle to the ultrasonic sensor; The ultrasonic sensor is used to obtain the distances Y1 and Y2 between the two ultrasonic sensors and the wall respectively, and a change angle threshold ΔY is set; When |Y1-Y2|≤ΔY, the spraying operation is performed, and after the spraying is completed, the automatic spraying machine for indoor decoration walls is moved to the next spraying position according to the extracted color difference edge line; When |Y1-Y2|>ΔY, the controller controls the electric wheel to drive the automatic sprayer for interior decoration walls to rotate around the Z axis, so that |Y1-Y2|≤ΔY, and then the spraying operation is performed. After the spraying is completed, the automatic sprayer for interior decoration walls is moved to the next spraying position according to the extracted color difference edge line.

2. The automatic spraying machine for indoor wall decoration according to claim 1 is characterized in that: The secondary frame comprises: A secondary frame, which is transmission-connected to the primary frame through a primary lifting mechanism, and is used to enable the secondary frame to be lifted and lowered along the Z-axis direction of the primary frame; A secondary slide rail, which is arranged on the secondary frame and along the Z-axis direction; The secondary driving mechanism is arranged on the secondary frame and is connected to the spraying base in a transmission manner so as to drive the spraying base to perform lifting movement along the Z-axis direction.

3. The automatic spraying machine for indoor wall decoration according to claim 2 is characterized in that: The secondary framework includes: A secondary vertical pole, the secondary vertical pole is arranged along the Z-axis direction, and the secondary slide rail is arranged on the secondary vertical pole; A secondary pole connector, through which the top ends of a plurality of secondary poles are connected, is used to enable the secondary frame to form a frame structure supported by a plurality of secondary poles.

4. The automatic spraying machine for indoor wall decoration according to claim 2 is characterized in that: The primary frame comprises: A bottom plate, the bottom of which is supported by electric wheels; The first-level vertical rod is arranged along the Z-axis direction and is set above the bottom plate. The first-level vertical rod is transmission-connected with the second-level frame through the first-level lifting mechanism, and is used to drive the second-level frame to perform lifting action along the Z-axis direction.

5. The automatic spraying machine for indoor wall decoration according to claim 4 is characterized in that: The spraying unit also includes: A spraying frame, the spraying frame is arranged on the spraying base, the spray head is arranged on the spraying frame, and the spraying frame is used to drive the spray head to selectively move along the X-axis and / or the Y-axis; Wherein, a projection unit is provided on the spraying machine frame or the spraying base; The automatic spraying machine for indoor decoration walls also includes a controller for controlling the nozzle and the spraying machine frame. The controller is respectively communicated with the electric wheel and the ultrasonic sensor, and is used to control the electric wheel to drive the automatic spraying machine for indoor decoration walls to make a specified translation according to the distance data. The specified translation is a tangent translation from the midpoint of the line connecting the two ultrasonic sensors to the wall point where the orthographic projection of the wall is located; the controller is also respectively communicated with the image acquisition unit and the projection unit, and is used to control the projection unit to project onto the wall and control the image acquisition unit to obtain image data on the wall.

6. The automatic spraying machine for indoor wall decoration according to claim 5 is characterized in that: The nozzle comprises: A nozzle fixing frame, which is rotatably arranged on the spraying machine frame and is used to enable the nozzle fixing frame to rotate around the X-axis or the Y-axis; A nozzle, which is arranged on a nozzle fixing frame and is used for spraying the wall surface; The image acquisition unit is arranged on the upper side of the nozzle fixing frame and corresponds to the nozzle on the nozzle fixing frame up and down; at least two ultrasonic sensors are respectively arranged on both sides of the nozzle fixing frame; the directions of the ultrasonic sensor, the nozzle and the image acquisition unit are all arranged in parallel.

7. A method for automatic spraying of indoor decoration walls based on machine vision, characterized in that: Using the automatic spraying machine for indoor decoration wall surface as claimed in claim 5 or 6, the automatic spraying method for indoor decoration wall surface comprises the following operations: A coordinate system is established with the center of the spraying machine, wherein the width direction of the spraying machine is the X-axis direction, the forward spraying direction of the spraying machine is the Y-axis direction, and the height direction of the spraying machine is the Z-axis direction; Move the indoor decoration wall automatic spraying machine to the wall to be sprayed, so that the spraying part faces the wall to be sprayed; Using an image acquisition unit to capture a wall image, extracting specified features in the wall image through a controller, and calculating coordinate data of the specified features; the specified features include cracks, color difference blocks, and color difference edges; The ultrasonic sensor is used to obtain the distances Y1 and Y2 between the two ultrasonic sensors and the wall respectively, and a change angle threshold ΔY is set; When |Y1-Y2|≤ΔY, the spraying operation is performed, and after the spraying is completed, the automatic spraying machine for indoor decoration walls is moved to the next spraying position according to the extracted color difference edge line; When |Y1-Y2|>ΔY, the controller controls the electric wheel to drive the automatic sprayer for interior decoration walls to rotate around the Z axis, so that |Y1-Y2|≤ΔY, and then the spraying operation is performed. After the spraying is completed, the automatic sprayer for interior decoration walls is moved to the next spraying position according to the extracted color difference edge line.

8. The method for automatic spraying of indoor decoration walls based on machine vision according to claim 7 is characterized in that: Before spraying, the connection between the spraying part and the spraying base is moved to an initial position, and the initial position satisfies the condition that the distance from the connection to the plane in the Z-axis direction where the edge of the spraying base close to the wall is located is greater than 0; During spraying, the spray head starts spraying from a side of the spray base close to the color difference edge line, and when the camera captures another color difference edge line, the spray area of ​​the spray head stops at the other color difference edge line.

9. The method for automatic spraying of indoor decoration walls based on machine vision according to claim 7 is characterized in that: The image acquisition unit and the projection unit form a structured light system to obtain depth data of the wall surface, wherein before spraying, the projection unit uses a single projection, and the controller extracts the corner position information according to the depth data; During spraying, the controller controls the spraying area of ​​the nozzle to stop at the wall corner position and detects the positive corner and the negative corner of the wall according to the depth data.

10. The method for automatic spraying of indoor decoration walls based on machine vision according to claim 9 is characterized in that: When a positive corner of the wall is detected, perform the following operations after spraying: Let s be the spraying distance from the sprayer to the wall; The spraying part returns to the center position in the Z-axis direction on the spraying base; the controller controls the electric wheel to drive the spraying machine to move to a position where the orthographic projection of the midpoint of the line connecting the two ultrasonic sensors to the wall falls on the corner of the wall, and obtains the depth data at the position, and obtains the angle θ1 of the positive corner according to the depth data; At this time, the sprayer continues to move L1 in the predetermined direction from the self-judgment position to the safety position; continues to move L2 in the predetermined direction from the safety position to the corner position; after the sprayer rotates by an angle θ1, the spraying direction of the sprayer nozzle is perpendicular to the plane of the other wall, and spraying is performed along the other wall at the corner; During spraying, the ultrasonic sensor detects the distance from the sprayer to the wall in real time, and the controller controls the electric wheel to correct the direction of the entire sprayer, so that the spraying distance from the sprayer to the wall remains at s; Among them, L1 is 1 / 2 of the overall width W of the spraying machine; L2=s*tan(135°-θ1), 90°≤θ1<180°; When a wall concave corner is detected, perform the following operations after spraying: The spraying part returns to the center position in the Z-axis direction on the spraying base, obtains the depth data at this position, and obtains the angle θ2 of the inner corner; the controller controls the electric wheel to drive the sprayer to retreat L3 in the X-axis and Y-axis directions respectively; the rotation angle of the sprayer is β=(180°-θ2), 90°≤θ2<180°; the spraying direction of the sprayer nozzle is perpendicular to the plane where the other wall is located; in the width direction of the sprayer, the controller controls the electric wheel to drive the sprayer to move L4 in the X-axis direction, so that the positive projection of the midpoint of the line connecting the two ultrasonic sensors to the wall falls on the corner of the wall, and this position is recorded as the transfer position, and the sprayer continues to move 1 / 2 of the overall width W of the sprayer in the X-axis direction from the transfer position; In the Y-axis direction, the sprayer moves forward so that the spraying distance from the sprayer to the wall is s, and the spraying direction of the sprayer nozzle is perpendicular to the plane of the other wall, and the spraying is performed along the other wall at the corner; Among them, L3≥D / 2-W / 2, D is the maximum width dimension on the Z-axis section of the spray machine.

Images