Method for improving paint usage amount and paint TRS of single product on coating line

Abstract

The invention provides a paint usage amount and paint TRS improvement method for a single product of a coating line, and the method comprises the steps: importing a production log of a coating robot in the coating line into a paint usage amount and paint TRS improvement system for the single product of the coating line; a paint BOM accounting module in the system calculates the paint consumption of a single product of a coating line according to a production log of a coating robot, a paint TRS accounting module calculates the theoretical weight dosage of the single product according to data stored in a basic data module, and the paint utilization rate is calculated according to the theoretical weight dosage of the single product and data output by the paint BOM accounting module. The paint improvement comparison module compares the theoretical volume dosage of the single piece with the difference of the paint output of the single piece of the coating spraying robot according to the theoretical volume dosage of the single piece, and the coating improvement space is judged; according to the method, data changes can be monitored quickly and constantly, the paint utilization rate of a single product and the actual paint consumption change trend of the single product are analyzed quickly and efficiently, and the working efficiency and the problem analysis ability of personnel are improved.

Description

Technical Field

[0001] The invention belongs to the field of digital management systems; specifically, it relates to a method for improving the paint usage and paint TRS of a single product in a coating line. Background Art

[0002] The existing coating line requires manual calculation of the paint usage of a single product. The data volume is huge, time-consuming and labor-intensive. In addition, due to the uncontrollability of manual calculation, transparent control cannot be achieved in the area of ​​spray paint usage on the coating line. Summary of the invention

[0003] In view of the above-mentioned technical problems and defects, the purpose of the present invention is to provide a method for improving the paint usage and paint TRS of a single product on a coating line. The method can quickly monitor data changes in real time, quickly and efficiently analyze the paint utilization rate of a single product and the actual paint consumption change trend of a single product, thereby improving the work efficiency and problem analysis ability of personnel, and providing a systematic and comprehensive data analysis to solve problems such as transparent monitoring of paint usage, material inventory analysis, and paint improvement point mining, so that engineers can quickly analyze the causes based on the data, respond, and provide optimized solutions; at the same time, it ensures transparent monitoring in the field of coating and spraying paint, effectively avoiding the occurrence of paint waste problems.

[0004] To achieve the above object, the present invention adopts the following technical solution:

[0005] A method for improving the paint usage and paint TRS of a single product on a coating line, the method comprising the following steps:

[0006] Step 1. Import the production log of the painting spraying robot in the painting line into the paint usage of a single product in the painting line and the paint TRS improvement system; wherein the paint usage of a single product in the painting line and the paint TRS improvement system include a paint BOM calculation module, a paint TRS calculation module, a paint improvement comparison module, a robot log recording module, and a basic data module;

[0007] Among them, the paint BOM accounting module is used to calculate the paint consumption of a single product of the painting line according to the production log of the painting spraying robot;

[0008] The paint TRS calculation module is used to calculate the theoretical weight usage of a single piece according to the data stored in the basic data module, and calculate the paint utilization rate according to the theoretical weight usage of a single piece and the data output by the paint BOM calculation module;

[0009] The paint improvement comparison module is used to compare the difference between the theoretical volume usage of a single piece and the paint discharge volume of a single piece by the painting spraying robot according to the theoretical volume usage of a single piece, so as to determine the improvement space of the painting;

[0010] The robot log recording module is used to record the production log information of the painting spraying robot processed by the system;

[0011] The basic data module includes a color & program number main table, a paint density table, a paint weight solid content table, a paint volume ratio table, and a product area and film thickness table;

[0012] The color & program number master table is used to bind a program number in the production log of the painting spray robot on different painting lines with the vehicle model, product, number of pieces per vehicle, color, primer color number, color paint color number, and clear coat color number;

[0013] The paint density table is used to store density information of each component in the paint used by different coating lines;

[0014] The paint weight solid content table is used to store the weight solid content information of the main agent and curing agent in the paint used by different coating lines;

[0015] The paint volume ratio table is used to store the volume information of each component in the paint used by different coating lines;

[0016] The product area and film thickness table is used to store product area and film thickness information processed by different coating lines;

[0017] Step 2. The paint BOM calculation module reads the key data in the production log of the painting spraying robot and converts the read key data according to the color & program number master table; the key data includes the program number and the paint discharge volume of the single vehicle bound to the vehicle model, product, number of pieces per vehicle, color, primer color number, color paint color number, and varnish color in the color & program number master table;

[0018] Step 3. The paint BOM calculation module calculates the single-piece spraying mixed flow rate based on the paint output of the painting spray robot and the number of pieces per vehicle, and then reads the volume ratio of each component of the paint used in the corresponding painting line according to the vehicle model, product, number of pieces per vehicle, and color, splits the mixed flow rate into the flow rates of each component of the paint, and then calculates the actual weight usage of each component in the paint according to the density of each component in the paint;

[0019] Step 4. The paint TRS calculation module reads the product area, primer minimum film thickness, color paint minimum film thickness, and clear coat minimum film thickness of the corresponding painting line according to the vehicle model, product, number of pieces per vehicle, and color; calculates the solidified volume of a single layer of paint according to the film thickness and product area, and then reversely infers the theoretical volume usage of a single piece of paint according to the volume solid content information of the main agent and curing agent in the paint. The calculation formula is:

[0020] Theoretical paint volume usage per piece = minimum film thickness of a single paint layer × sprayed product area / (volume solid content of main agent in paint × volume of main agent in paint + volume solid content of curing agent in paint × volume of curing agent in paint) / minimum painting rate;

[0021] Volume solid content of main agent in paint = volume of main agent - (volume of main agent × density of main agent × (1 - weight solid content of main agent) / density of diluent in paint) / volume of main agent;

[0022] Volume solid content of curing agent in paint = volume of curing agent - (volume of curing agent × density of curing agent × (1 - weight solid content of curing agent) / density of diluent in paint) / volume of curing agent;

[0023] Step 5. Calculate the theoretical weight of a single piece based on the theoretical volume of paint and the density of each component in the paint. Calculate the paint TRS (paint utilization rate) based on the theoretical weight of a single piece and the actual weight of paint calculated by the paint BOM calculation module. The calculation formula is:

[0024] Paint TRS = theoretical weight of a single piece / actual weight;

[0025] Step 6. The paint improvement comparison module calculates the theoretical volume usage of a single vehicle according to the theoretical volume usage of a single piece and the number of pieces per vehicle, compares the theoretical volume usage of a single vehicle with the paint discharge volume of a single vehicle by the painting spraying robot, and analyzes the painting situation of the single vehicle product. If the theoretical volume usage of a single vehicle is significantly smaller than the actual volume usage, the painting process is improved;

[0026] Step 7. Repeat steps 1 to 6, and compare the paint TRS before and after the coating process improvement, and select the coating process with the highest paint TRS.

[0027] As a preferred embodiment of the present invention, the paint is divided into primer, color paint and varnish, and the paint includes a main agent, a diluent, a slow-drying agent and a curing agent, wherein the main agent refers to the main component in the paint.

[0028] As a preferred embodiment of the present invention, the minimum painting rate in step 4 is set according to the painting spray robot, the minimum painting rate of air gun spraying is 30%, the minimum painting rate of spraying without electric rotary cup is 40%, and the minimum painting rate of electric rotary cup spraying is 65%; the ratio of combined spraying with electric rotary cup and air gun is 6:4, that is, the minimum painting rate of one electric rotary cup and one air gun is 0.51.

[0029] As a preferred embodiment of the present invention, the paint BOM calculation module, the paint TRS calculation module, and the paint improvement comparison module are all provided with a search unit, and the search unit filters the data that meets the filtering conditions according to the area (production site), line, vehicle model, product, number of pieces per vehicle, color, and verification time.

[0030] Advantages and beneficial effects of the present invention:

[0031] (1) The system provided by the present invention can quickly process a large amount of data, combine independent data, and output the paint utilization rate of a single product and the actual paint consumption of a single product, which is convenient for analysis and use.

[0032] (2) The data processing of the present invention has good timeliness and can perform big data calculations and output corresponding results every day, which solves the problem that manual calculations can only be performed monthly due to labor efficiency issues, and achieves daily monitoring and auditing improvements.

[0033] (3) The data dimension diversity of the present invention is to screen and generate the paint utilization rate of a single product and the actual paint consumption of a single product based on the production site, vehicle model, color, and time, so as to provide effective data analysis for optimization and adjustment.

[0034] (4) The method provided by the present invention can monitor the paint property data of the paint manufacturer upward and the paint consumption data of the on-site engineering personnel downward. By comparing and analyzing the paint utilization rate of a single product and the actual paint consumption of a single product output by the system, the method can quickly analyze and identify the theoretical and actual differences of a line and a product, so as to track and improve them.

[0035] (5) The present invention can quickly monitor data changes in real time, quickly and efficiently analyze the paint utilization rate of a single product and the actual paint consumption trend of a single product, thereby improving the work efficiency and problem analysis ability of personnel, and providing a systematic and comprehensive data analysis to solve problems such as transparent monitoring of paint usage, material inventory analysis, and paint improvement point mining, so that engineers can quickly analyze the causes based on the data, respond, and provide optimized solutions; at the same time, it ensures transparent monitoring in the field of painting and spraying paint, effectively avoiding the occurrence of paint waste.

[0036] (6) The present invention can comprehensively control the usage of a single product paint from the entire process of source control (paint manufacturer) - process control (bumper manufacturing unit) - terminal control (material warehouse). By real-time monitoring of changes in single product paint consumption data, data analysis results can be quickly obtained, providing effective data support for solving the paint consumption problem, ensuring transparent monitoring in the field of painting and spraying paint, and effectively avoiding the occurrence of paint waste problems. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a schematic diagram of the paint usage and paint TRS improvement system for a single product on the painting line. DETAILED DESCRIPTION

[0038] In order to enable those skilled in the art to better understand the technical solution and advantages of the present invention, the present application is described in detail below in conjunction with the accompanying drawings, but it is not intended to limit the protection scope of the present invention.

[0039] like Figure 1 As shown, this embodiment provides a method for improving the paint usage and paint TRS of a single product in a coating line, and the method comprises the following steps:

[0040] Step 1. Import the production log of the painting spraying robot in the painting line into the paint usage of a single product in the painting line and the paint TRS improvement system; wherein the paint usage of a single product in the painting line and the paint TRS improvement system include a paint BOM calculation module, a paint TRS calculation module, a paint improvement comparison module, a robot log recording module, and a basic data module;

[0041] Among them, the paint BOM accounting module is used to calculate the paint consumption of a single product of the painting line according to the production log of the painting spraying robot;

[0042] The paint TRS calculation module is used to calculate the theoretical weight usage of a single piece according to the data stored in the basic data module, and calculate the paint utilization rate according to the theoretical weight usage of a single piece and the data output by the paint BOM calculation module;

[0043] The paint improvement comparison module is used to compare the difference between the theoretical volume usage of a single piece and the paint discharge volume of a single piece by the painting spraying robot according to the theoretical volume usage of a single piece, so as to determine the improvement space of the painting;

[0044] The robot log recording module is used to record the production log information of the painting spraying robot processed by the system;

[0045] The basic data module includes a color & program number main table, a paint density table, a paint weight solid content table, a paint volume ratio table, and a product area and film thickness table;

[0046] The color & program number master table is used to bind a program number in the production log of the painting spray robot on different painting lines with the vehicle model, product, number of pieces per vehicle, color, primer color number, color paint color number, and clear coat color number;

[0047] The paint density table is used to store density information of each component in the paint used by different coating lines;

[0048] The paint weight solid content table is used to store the weight solid content information of the main agent and curing agent in the paint used by different coating lines;

[0049] The paint volume ratio table is used to store the volume information of each component in the paint used by different coating lines;

[0050] The product area and film thickness table is used to store product area and film thickness information processed by different coating lines;

[0051] Step 2. The paint BOM calculation module reads the key data in the production log of the painting spraying robot and converts the read key data according to the color & program number master table; the key data includes the program number and the paint discharge volume of the single vehicle bound to the vehicle model, product, number of pieces per vehicle, color, primer color number, color paint color number, and varnish color in the color & program number master table;

[0052] Step 3. The paint BOM calculation module calculates the single-piece spraying mixed flow rate based on the paint output of the painting spray robot and the number of pieces per vehicle, and then reads the volume ratio of each component of the paint used in the corresponding painting line according to the vehicle model, product, number of pieces per vehicle, and color, splits the mixed flow rate into the flow rates of each component of the paint, and then calculates the actual weight usage of each component in the paint according to the density of each component in the paint;

[0053] Step 4. The paint TRS calculation module reads the product area, primer minimum film thickness, color paint minimum film thickness, and clear coat minimum film thickness of the corresponding painting line according to the vehicle model, product, number of pieces per vehicle, and color; calculates the solidified volume of a single layer of paint according to the film thickness and product area, and then reversely infers the theoretical volume usage of a single piece of paint according to the volume solid content information of the main agent and curing agent in the paint. The calculation formula is:

[0054] Theoretical paint volume usage per piece = minimum film thickness of a single paint layer × sprayed product area / (volume solid content of main agent in paint × volume of main agent in paint + volume solid content of curing agent in paint × volume of curing agent in paint) / minimum painting rate;

[0055] Volume solid content of main agent in paint = volume of main agent - (volume of main agent × density of main agent × (1 - weight solid content of main agent) / density of diluent in paint) / volume of main agent;

[0056] Volume solid content of curing agent in paint = volume of curing agent - (volume of curing agent × density of curing agent × (1 - weight solid content of curing agent) / density of diluent in paint) / volume of curing agent;

[0057] Step 5. Calculate the theoretical weight of a single piece based on the theoretical volume of paint and the density of each component in the paint. Calculate the paint TRS (paint utilization rate) based on the theoretical weight of a single piece and the actual weight of paint calculated by the paint BOM calculation module. The calculation formula is:

[0058] Paint TRS = theoretical weight of a single piece / actual weight;

[0059] Step 6. The paint improvement comparison module calculates the theoretical volume usage of a single vehicle according to the theoretical volume usage of a single piece and the number of pieces per vehicle, compares the theoretical volume usage of a single vehicle with the paint discharge volume of a single vehicle by the painting spraying robot, and analyzes the painting situation of the single vehicle product. If the theoretical weight usage of a single vehicle is significantly less than the actual weight usage, the painting process is improved;

[0060] Step 7. Repeat steps 1 to 6, and compare the paint TRS before and after the coating process improvement, and select the coating process with the highest paint TRS.

[0061] In this embodiment, the paint is divided into primer, color paint and varnish, and the paint includes a main agent, a diluent, a slow-drying agent and a curing agent, wherein the main agent refers to the main component in the paint.

[0062] In this embodiment, the minimum painting rate in step 4 is set according to the painting spray robot, the minimum painting rate of air gun spraying is 30%, the minimum painting rate of spraying without electric rotary cup is 40%, and the minimum painting rate of spraying with electric rotary cup is 65%; the ratio of combined spraying with electric rotary cup and air gun is 6:4, that is, the minimum painting rate of one electric rotary cup and one air gun is 0.51.

[0063] In this embodiment, the paint BOM calculation module, the paint TRS calculation module, and the paint improvement comparison module are all provided with a search unit, which filters data that meets the filtering conditions according to the area (production site), line, vehicle model, product, number of pieces per vehicle, color, and verification time, thereby providing effective data support for solving the paint consumption problem.

[0064] The above specific examples are used to illustrate the present invention, which is only used to help understand the present invention and is not intended to limit the present invention. For those skilled in the art of the present invention, according to the idea of ​​the present invention, some simple deductions, deformations or substitutions can be made. Therefore, the protection scope of the present invention shall be based on the protection scope of the claims.

Claims

1. A method for improving the paint usage and paint TRS of a single product on a coating line, characterized in that: The method comprises the following steps: Step 1. Import the production log of the painting spraying robot in the painting line into the paint usage of a single product in the painting line and the paint TRS improvement system; wherein the paint usage of a single product in the painting line and the paint TRS improvement system include a paint BOM calculation module, a paint TRS calculation module, a paint improvement comparison module, a robot log recording module, and a basic data module; Among them, the paint BOM accounting module is used to calculate the paint consumption of a single product of the painting line according to the production log of the painting spraying robot; The paint TRS calculation module is used to calculate the theoretical weight usage of a single piece according to the data stored in the basic data module, and calculate the paint utilization rate according to the theoretical weight usage of a single piece and the data output by the paint BOM calculation module; The paint improvement comparison module is used to compare the difference between the theoretical volume usage of a single piece and the paint discharge volume of a single piece by the painting spraying robot according to the theoretical volume usage of a single piece, so as to determine the improvement space of the painting; The robot log recording module is used to record the production log information of the painting spraying robot processed by the system; The basic data module includes a color & program number main table, a paint density table, a paint weight solid content table, a paint volume ratio table, and a product area and film thickness table; The color & program number master table is used to bind a program number in the production log of the painting spray robot on different painting lines with the vehicle model, product, number of pieces per vehicle, color, primer color number, color paint color number, and clear coat color number; The paint density table is used to store density information of each component in the paint used by different coating lines; The paint weight solid content table is used to store the weight solid content information of the main agent and curing agent in the paint used by different coating lines; The paint volume ratio table is used to store the volume information of each component in the paint used by different coating lines; The product area and film thickness table is used to store product area and film thickness information processed by different coating lines; Step 2. The paint BOM calculation module reads the key data in the production log of the painting spraying robot and converts the read key data according to the color & program number master table; the key data includes the program number and the paint discharge volume of the single vehicle bound to the vehicle model, product, number of pieces per vehicle, color, primer color number, color paint color number, and varnish color in the color & program number master table; Step 3. The paint BOM calculation module calculates the single-piece spraying mixed flow rate based on the paint output of the painting spray robot and the number of pieces per vehicle, and then reads the volume ratio of each component of the paint used in the corresponding painting line according to the vehicle model, product, number of pieces per vehicle, and color, splits the mixed flow rate into the flow rates of each component of the paint, and then calculates the actual weight usage of each component in the paint according to the density of each component in the paint; Step 4. The paint TRS calculation module reads the product area, primer minimum film thickness, color paint minimum film thickness, and clear coat minimum film thickness of the corresponding painting line according to the vehicle model, product, number of pieces per vehicle, and color; calculates the solidified volume of a single layer of paint according to the film thickness and product area, and then reversely infers the theoretical volume usage of a single piece of paint according to the volume solid content information of the main agent and curing agent in the paint. The calculation formula is: Theoretical paint volume usage per piece = minimum film thickness of a single paint layer × sprayed product area / (volume solid content of main agent in paint × volume of main agent in paint + volume solid content of curing agent in paint × volume of curing agent in paint) / minimum painting rate; Volume solid content of main agent in paint = volume of main agent - (volume of main agent × density of main agent × (1 - weight solid content of main agent) / density of diluent in paint) / volume of main agent; Volume solid content of curing agent in paint = volume of curing agent - (volume of curing agent × density of curing agent × (1 - weight solid content of curing agent) / density of diluent in paint) / volume of curing agent; Step 5. Calculate the theoretical weight of a single piece based on the theoretical volume of paint and the density of each component in the paint. Calculate the paint TRS (paint utilization rate) based on the theoretical weight of a single piece and the actual weight of paint calculated by the paint BOM calculation module. The calculation formula is: Paint TRS = theoretical weight of a single piece / actual weight; Step 6. The paint improvement comparison module calculates the theoretical volume usage of a single vehicle according to the theoretical volume usage of a single piece and the number of pieces per vehicle, compares the theoretical volume usage of a single vehicle with the paint discharge volume of a single vehicle by the painting spraying robot, and analyzes the painting situation of the single vehicle product. If the theoretical volume usage of a single vehicle is significantly smaller than the actual volume usage, the painting process is improved; Step 7. Repeat steps 1 to 6, and compare the paint TRS before and after the coating process improvement, and select the coating process with the highest paint TRS.

2. A method for improving the paint usage and paint TRS of a single product on a coating line according to claim 1, characterized in that: The paint is divided into primer, color paint and varnish, and the paint includes a main agent, a diluent, a slow-drying agent and a curing agent, wherein the main agent refers to the main component in the paint.

3. A method for improving the paint usage and paint TRS of a single product on a coating line according to claim 1, characterized in that: The minimum painting rate in step 4 is set according to the painting spray robot. The minimum painting rate of air gun spraying is 30%, the minimum painting rate of spraying without electro-rotating cup is 40%, and the minimum painting rate of spraying with electro-rotating cup is 65%; the ratio of combined spraying with electro-rotating cup and air gun is 6:4, that is, the minimum painting rate of one electro-rotating cup and one air gun is 0.

51.

4. A method for improving the paint usage and paint TRS of a single product in a coating line according to claim 1, characterized in that: The paint BOM calculation module, paint TRS calculation module, and paint improvement comparison module are all provided with a search unit, and the search unit filters data that meets the screening conditions according to region, line, vehicle model, product, number of pieces per vehicle, color, and verification time.

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