Ship green coating simulation training system

Abstract

The invention discloses a ship green coating simulation training system, and belongs to the technical field of coating system training. The system is a comprehensive coating simulation VR training system integrating spraying, roller coating and sand blasting. The concept of coating defects is added into the spraying training module, and spraying defects such as orange peel sagging generated in actual work are projected into the training system, so that spraying training is more real and visual. In sand blasting simulation, according to the principles of corrosion occurrence and development, corrosion and zinc salt samples of different degrees actually sampled on site, and the recording of the treatment process of the corrosion and zinc salt samples according to an actual sand blasting process, parameters of different defect severity degrees are restored, and the distribution conditions of corrosion and zinc salt defects on a plane are established; and recording is carried out according to the surface state of the workpiece in the actual sand blasting rust removal process, and the rust removal process is achieved and presented. According to the system, technologies such as virtual reality enhancement, simulation practical training and panoramic sound distribution surrounding are adopted, and a virtual and real training environment is provided for learners.

Description

Technical Field

[0001] The invention relates to a ship green painting simulation training system, which belongs to the technical field of painting system training. Background Art

[0002] Virtual reality (VR) training is an immersive learning experience that engages learners in real-world scenarios to teach important skills and concepts. Research shows that humans are hardwired to learn actively. Our brains learn better when we are engaged and emotionally invested in the learning process.

[0003] Immersive learning takes advantage of this principle - it involves creating an experience that puts the learner at the heart of the subject. VR training can increase learner engagement, better understanding, and improved knowledge retention in a safer, more cost-effective way while reducing training time. This advanced training technology is applicable in areas that are difficult, dangerous, or expensive to simulate in real life.

[0004] VR\AR technology integrates computer graphics technology, simulation technology, sensor technology, display technology and other information technologies, and can create a virtual information environment in a multi-dimensional information space, so that users can have an immersive feeling, have the ability to interact with the environment, and help inspire thinking. This simulation has two basic characteristics, namely "immersion" and "interaction". The "immersion" feature requires that the three-dimensional virtual environment created by the computer can enable the "participants" to experience the environment wholeheartedly; the "interaction" feature mainly refers to the participants using special equipment to realize the interactive inspection and operation of entities in the virtual environment with human natural skills.

[0005] VR\AR technology has had a revolutionary impact on the shipbuilding industry. This technology has gradually begun to be applied in the fields of ship design and construction, education and training, and ship operations. Summary of the invention

[0006] With the application of VR technology in the manufacturing site, the present invention provides a ship green painting simulation training system, and employees can conduct repeated training without being restricted by time and space / location. Enterprises will also create a safe and environmentally friendly training environment through these measures.

[0007] The technical solution adopted by the present invention is: a ship green painting simulation training system, including a PC host, a VR virtual reality head-mounted experience device, a space positioning base station, a space positioning terminal sensor, a spraying simulation training device, a roller coating simulation training device, a sandblasting simulation training device, and a simulation training painting workpiece.

[0008] The spatial positioning base station is fixedly installed at a high place in the training environment, emitting modulated invisible laser into the space to realize the function of spatial positioning lighthouse.

[0009] The spatial positioning terminal sensor is installed in the fixed position of the spraying simulation training device, roller coating simulation training device, sandblasting simulation training device and the simulated training painting workpiece. By receiving the modulated laser signal of the spatial positioning base station, it calculates the relative position and posture data with the spatial positioning base station in real time, realizes the digitization of its position and posture, and transmits the data to the VR virtual reality head-mounted experience device through Bluetooth signal, and finally connects it to the PC host to realize the positioning and posture functions of each component of the system. The ship green painting simulation training software is set in the PC host.

[0010] The VR virtual reality head-mounted experience device receives the signal from the spatial positioning base station, calculates its position and posture in space, and connects the data to the ship green painting simulation training software. According to its position and posture in space, the ship green painting simulation training software calculates the position and posture of each component in real time, and transmits the picture that the VR virtual reality head-mounted experience device needs to present back in real time. Ultimately, the user can use the VR virtual reality head-mounted experience device to freely watch and move in the virtual scene in an immersive training environment, and can operate the spray simulation training device, roller coating simulation training device, sandblasting simulation training device and simulated training painting workpieces, and perform related training subjects on the simulated training painting workpieces.

[0011] The spray simulation training device is similar in appearance to the spray gun actually used for painting. A spatial positioning terminal sensor is installed at a fixed position to realize the spatial positioning function. A touch-type electronic switch is added to the spray trigger switch to transmit the spray switch signal back to the ship green painting simulation training software. The data realization of the spray simulation is based on the relationship between the nozzle pressure and the jet morphology, the effective spray distance, the distribution of the coating thickness of one spray, and the distribution of the coating thickness of multiple sprays obtained in the standard spraying experiment, and the corresponding mathematical model is established. In the ship green painting simulation training software, according to the user's actual operation of the switch, position, and posture of the spray simulation training device, according to the nozzle jet distribution, the speed and flow direction of each small jet, as well as the contact point coordinates of each jet on the workpiece surface are calculated in real time to simulate the adhesion of small droplets of paint on the workpiece surface. Then, in the surface visual material of the simulated training painting workpiece, the coating thickness of each pixel is stored to realize the distribution heat map of the coating thickness of the sprayed surface. When the coating thickness reaches or exceeds the corresponding threshold, the corresponding orange peel and sagging effects are presented through the processing of multi-layer surface visual materials, thereby achieving the purpose of spray simulation training.

[0012] The appearance of the roller painting simulation training device is similar to the roller brush actually used in painting. The spatial positioning end sensor is installed at a fixed position to realize the spatial positioning function. The roller painting process itself relies on the contact between the roller brush and the surface of the workpiece. Therefore, only the relative relationship between its position and posture and the simulated training painting workpiece is required. The ship green painting simulation training software can calculate the coating situation of the roller painting process. The data realization of the roller painting simulation is based on the full coating thickness-length test data of the empty plate with one dip and the coating thickness-length test data of the second dip in the standard roller painting experiment, and the corresponding mathematical model is established. In the ship green painting simulation training software, the real-time film thickness data is stored in the surface visual material of the simulated training painting workpiece. Combined with the dynamic paint amount data on the roller painting simulation training device, the surface film thickness of the workpiece after the roller brush is applied and the new roller brush paint amount are calculated according to the mathematical model, thereby realizing the characteristics of the roller painting process, that is, the paint can be applied or the paint can be blurred. Then, in the surface visual material of the simulated training painting workpiece, the distribution heat map of the film thickness of the roller coating surface is presented to achieve the purpose of the roller painting simulation training.

[0013] The sandblasting simulation training device is similar in appearance to the actual nozzle used in the rust removal process. A spatial positioning terminal sensor is installed at a fixed position to realize the spatial positioning function. A touch-type electronic switch is added to the nozzle trigger switch to transmit the spray switch signal back to the ship green coating simulation training software. At the end, the high-speed DC fan is linked with the touch-type electronic switch, and the recoil feedback is realized through the high-speed DC fan blowing to enhance the experience effect. The data realization of the sandblasting simulation first needs to be based on the principle of rust occurrence and development, as well as the different degrees of rust, zinc salt and other samples actually sampled on site, and according to the actual sandblasting process. The records of its processing process restore the parameters of different defect severity and establish a mathematical model of the distribution of rust and zinc salt defects on a two-dimensional plane. Secondly, it is necessary to record the surface state of the workpiece after different nozzle pressures and sandblasting times in the actual sandblasting rust removal process to realize the mathematical model of the rust removal process. In the ship green painting simulation training software, according to the input set rust degree, based on the defect mathematical model and the rust surface area, the defect distribution heat map is generated, and combined with computer visual surface material processing methods such as dynamic UV mapping, dynamic roughness mapping, dynamic area transparent mapping, etc., realistic rust and zinc salt effects are presented, and the rust data is recorded in the surface visual material; then according to the user's actual operation of the switch, position, and posture of the sandblasting simulation training device, according to the nozzle jet distribution, the speed and flow direction of each small jet, as well as the contact point coordinates of each jet on the workpiece surface are calculated in real time to simulate the collision and rust removal process of the sandblasting jet on the workpiece surface. Finally, in the surface visual material of the simulated training painted workpiece, and based on the rust residue data and paint residue data, the visual appearance of the workpiece surface after sandblasting is calculated to achieve the purpose of sandblasting simulation training.

[0014] Furthermore, the data realization of spray simulation is based on the relationship between nozzle pressure and jet morphology, effective spray distance, one-time spray coating thickness distribution, and multiple-time spray coating thickness distribution obtained in the standard spray experiment. The corresponding mathematical model is established as follows:

[0015] In the mathematical model, the physical process is divided into three stages: pressure squeezes the droplets to the nozzle to diffuse and form droplets, the droplets jet in the air, and the droplets adhere to different surfaces to form a paint film;

[0016] When the pressure squeezes the droplet to the nozzle and diffuses to form a droplet, the droplet diameter d 液 With pressure P, nozzle type T-type 喷嘴 , paint type coefficient k-type 油漆 Simplified to

[0017] d 液 =K-type 油漆 / (P × T-type 喷嘴 )

[0018] When a droplet is jetting in the air, the initial velocity v of the droplet in the air is 液 With pressure P, nozzle type T-type 喷嘴 , the speed coefficient kv relationship is:

[0019] v 液 =P × T-type 喷嘴 × kv

[0020] The process of forming a paint film after the droplet adheres to the surface can be simplified as the process of transforming a quasi-spherical droplet into a paint film with a certain uniform thickness; the paint film thickness Th 漆 With the attachment surface area S 漆 and droplet diameter d 液 The relationship is:

[0021] Th 漆 = π× (d 液 3 ) / (6×S 漆 )

[0022] Among them, the attachment surface area S 漆 Simplified to a constant of 1 square centimeter.

[0023] Furthermore, the calculation of the amount of paint used in the spray simulation training device is as follows: by establishing a mathematical model of nozzle droplet distribution, a mathematical model is established for the relationship between spray pressure, paint droplet distribution, and droplet diameter, the discrete distribution amount of nozzle droplets at each moment is calculated, and the total amount of paint used Q is obtained by statistical summary hour by hour. 涂料 ;

[0024] Q涂料 =∫Th 漆 ×S 漆 ×k-type 漆 ·dt

[0025] Th 漆 is the film thickness, S 漆 is the attachment surface area, k-type 油漆 is the paint type coefficient.

[0026] Furthermore, when the coating thickness reaches or exceeds a corresponding threshold, a corresponding orange peel and sagging effect is presented, specifically:

[0027] Through actual spraying experiments, data is recorded and a two-dimensional continuous mathematical model of spraying thickness, orange peel and sagging phenomena is established. When the surface paint film thickness exceeds a certain threshold, orange peel phenomenon occurs. When the degree of orange peel exceeds a certain threshold, threadhold 漆 When the flow phenomenon occurs;

[0028] The cellulite phenomenon is divided into the action area S 橘皮 , Local orange peel peak 橘皮 、Average local cellulite level Ave 橘皮 , the orange peel condition of the surface can be displayed and compared with the film thickness Th 漆 Make associations;

[0029] S 橘皮 =Area(Th 漆 >threadhold 漆 )

[0030] Peak 橘皮 = Max(Area(Th 漆 ))

[0031] Ave 橘皮 = Average(Area(Th 漆 ))

[0032] According to the local peak of cellulite 橘皮 Average level of local cellulite 橘皮 The deviation degree is used to dynamically draw the local orange peel pattern. That is, the larger the deviation degree, the more obvious the orange peel is and the stronger the bumps are.

[0033] Furthermore, a complete mathematical model is established from the roller brush dipping to the application on the workpiece surface. The specific process is as follows:

[0034] The simulated physical model adopts the assumption of conservation of paint mass, and also assumes that the paint on the roller brush is always uniform and the action of rolling is uniform. Then the thickness of the new paint film on the workpiece surface = fn_mix (the thickness of the old paint film on the workpiece surface, the thickness of the paint on the roller brush);

[0035] Calculation of roller brush paint thickness:

[0036] TH_brush = Q_brush × K_brush

[0037] Among them, TH_brush is the thickness of the paint on the roller brush, Q_brush is the amount of paint on the roller brush, and K_brush is the thickness coefficient of the paint on the roller brush; that is, the more paint on the roller brush, the thicker the paint thickness will be;

[0038] Calculation of the amount of paint applied by roller coating:

[0039] Delta_Q = (TH_surface_after-TH_surface_before) ×W_brush × Delta_L

[0040] Among them, W_brush is the coating width of the roller brush, TH_surface_before is the paint film thickness of the surface workpiece to be coated, and Delta_L is the minimum unit length of coating;

[0041] Each time the roller coating is applied, the new thickness of the workpiece surface TH_surface_after is:

[0042] TH_surface_after = fn× (TH_brush+TH_surface_before), where fn is fitted to 0.5 based on experimental results.

[0043] The amount of paint on the roller brush after rolling Q_brush_after

[0044] Q_brush_after= Q_brush - Delta_Q.

[0045] Furthermore, a mathematical model of the distribution of rust and zinc salt defects on a two-dimensional plane is established. Specifically, random rust starting points are set at the joints and the surface, and a random erosion time is set at each point to obtain the degree of rust at each random rust starting point. Then, according to the characteristics of the outward diffusion of the starting point, the rust is diffused around the surface to obtain the distribution of rust and zinc salt defects.

[0046] Furthermore, according to the actual sandblasting rust removal process, the surface state of the workpiece after different nozzle pressures and sandblasting times is recorded to realize the mathematical model of the rust removal process, which is specifically:

[0047] The sandblasting rust removal process is regarded as the reverse process of the spraying process. The rust removal thickness delta 锈 With blasting pressure P 喷砂 , Sand material rust removal coefficient k 喷砂 The relationship is as follows:

[0048] delta 锈 =P 喷砂 ×k 喷砂

[0049] Surface rust thickness Th 锈 Derusting thickness delta 锈 The relationship is:

[0050] Th 锈 = Th 锈-初始 - Min(Th 锈-初始 , ∫delta 锈 ·dt).

[0051] Compared with the prior art, the present invention has the following advantages:

[0052] Different from the previous VR training system of single spraying or sandblasting, the present invention is a comprehensive painting simulation VR training system integrating spraying, roller coating and sandblasting. And for the first time, it innovatively adopts the technology combining entity segmented model with roller coating VR training. It has achieved a simulation training method combining virtual and reality.

[0053] And for the first time, the concept of coating defects was innovatively added to the spraying training module. Spraying defects such as orange peel and sag generated in actual work were projected into the training system, making spraying training more realistic and intuitive.

[0054] This is done through the VR spraying operation training system. The VR virtual spraying system is a new way of spraying training. It uses VR, a popular black technology, to transform the traditional spraying training method and can effectively solve the problems of difficult spraying training, consumables, pollution, etc.

[0055] The system uses virtual reality enhancement, simulation training, panoramic sound distribution and surround technologies to provide learners with a virtual and real painting training environment. The entire operation process is carried out in the VR experience room, using advanced sensors and display equipment. After the spraying operator wears a VR headset, he can view the model segmentation while holding a high-simulation physical spray gun and moving his body to simulate the spraying operation. According to the learner's spraying posture, spray gun distance, angle, speed and other operation information, automatic collection and physical calculation are performed to automatically generate learning data and spraying training reports. This is conducive to learners' independent analysis and problem solving.

[0056] The high-speed DC fan is linked by a touch switch, and the airflow generated by the fan generates recoil feedback. VR virtual reality simulation technology is combined with positioning technology to numerically restore the posture and orientation of the handheld roller brush, and combined with the mathematical model of the roller brush coating process, the simulation training program is controlled to achieve an immersive interactive feedback-style intuitive training experience. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0058] Figure 1 It is the structural block diagram of the ship green painting simulation training system.

[0059] Figure 2 It is a flow chart of spraying simulation training.

[0060] Figure 3 It is a flowchart of roller coating simulation training.

[0061] Figure 4 It is a flow chart of sandblasting simulation training.

[0062] In the figure: 1. PC host, 2. VR virtual reality head-mounted experience device, 3. Space positioning base station, 4. Space positioning terminal sensor, 5. Spraying simulation training device, 6. Roller coating simulation training device, 7. Sandblasting simulation training device, 8. Simulation training of painting workpieces. DETAILED DESCRIPTION

[0063] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0064] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0065] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0066] Unless otherwise specifically stated, the relative arrangement of the parts and steps described in these embodiments, the numerical expressions and numerical values ​​do not limit the scope of the present invention. At the same time, it should be clear that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The technology, methods and equipment known to ordinary technicians in the relevant field may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be regarded as part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0067] In the description of the present invention, it is necessary to understand that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "lateral, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention: the directional words "inside and outside" refer to the inside and outside relative to the contours of each component itself.

[0068] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below their position devices or structures". Thus, the exemplary term "above" may include both "above" and "below". The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0069] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. If not otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0070] Figures 1 to 4 The system is shown as a ship green painting simulation training system, including a PC host 1, a VR virtual reality head-mounted experience device 2, a space positioning base station 3, a space positioning terminal sensor 4, a spraying simulation training device 5, a roller painting simulation training device 6, a sandblasting simulation training device 7, and a simulation training painting workpiece 8.

[0071] The space positioning base station 3 is fixedly installed at a high place in the training environment, and emits modulated invisible laser into the space to realize the space positioning lighthouse function.

[0072] The spatial positioning terminal sensor 4 is installed at fixed positions of the spraying simulation training device 5, the roller coating simulation training device 6, the sandblasting simulation training device 7 and the simulated training painting workpiece 8. By receiving the modulated laser signal of the spatial positioning base station 3, it calculates its relative position and posture data with the spatial positioning base station 3 in real time, realizes the digitization of its position and posture, and transmits the data to the VR virtual reality head-mounted experience device 2 through the Bluetooth signal, and finally connects it to the PC host 1 to realize the positioning and posture functions of each component of the system.

[0073] The VR virtual reality head-mounted experience device 2 receives the signal from the spatial positioning base station 3, calculates its position and posture in space, and connects the data to the PC host 1. According to its position and posture in space, the PC host 1 calculates the position and posture of each component in real time, and transmits the picture that the VR virtual reality head-mounted experience device 2 needs to present back in real time, so that the user can finally use the VR virtual reality head-mounted experience device 2 to freely watch and move in the virtual scene in an immersive training environment, and can operate the spraying simulation training device 5, the roller coating simulation training device 6, and the sandblasting simulation training device 7 to perform related training subjects on the simulated training painting workpiece 8.

[0074] Spraying simulation training: Change the offline training method of spraying to online training. It is completed through VR spraying operation training system. VR virtual spraying system is a new way of spraying training. It uses VR, a popular black technology, to change the traditional spraying training method and can effectively solve the problems of difficult spraying training, consumables, pollution, etc.

[0075] The system uses virtual reality enhancement, simulation training, panoramic sound distribution and surround technologies to provide learners with a virtual and real painting training environment. The entire operation process is carried out in the VR experience room, using advanced sensors and display equipment. After the spraying operator wears a VR headset, he can view the model segmentation while holding a high-simulation physical spray gun and moving his body to simulate the spraying operation. According to the learner's spraying posture, spray gun distance, angle, speed and other operation information, automatic collection and physical calculation are performed to automatically generate learning data and spraying training reports. This is conducive to learners' independent analysis and problem solving.

[0076] The spray simulation training device 5 is similar in appearance to the spray gun actually used for painting. A spatial positioning terminal sensor 4 is installed at a fixed position to realize the spatial positioning function. A touch-type electronic switch is added at its spray trigger switch to transmit the spray switch signal back to the PC host 1. The data realization of the spray simulation is based on the relationship between the nozzle pressure and the jet morphology, the effective spray distance, the coating thickness distribution of one spraying, and the coating thickness distribution of multiple spraying obtained in the standard spraying experiment, and the corresponding mathematical model is established.

[0077] In the mathematical model, the physical process is divided into the following three stages: pressure squeezes the droplets to diffuse into the nozzle to form droplets, the droplets jet in the air, and the droplets adhere to different surfaces to form a paint film.

[0078] According to experiments, the droplet diameter d 液 With pressure P, nozzle type T-type 喷嘴 , paint type coefficient k-type 油漆 Can be simplified to

[0079] d液 =K-type 油漆 / (P × T-type 喷嘴 )

[0080] The initial velocity v of the droplet jet in the air 液 With pressure P, nozzle type T-type 喷嘴 , the speed coefficient kv relationship is:

[0081] v 液 =P × T-type 喷嘴 × kv

[0082] The droplets in the air move in a parabolic motion with gravity and air resistance. In the actual production process, the nozzle is about 50cm~100cm away from the workpiece surface, and the initial velocity of the droplets is very large. After the droplet velocity decays too much, it cannot be painted. Therefore, the air resistance in the process can be ignored, and the movement of the droplets in the air can be simplified to a parabolic motion without resistance.

[0083] The process of forming a paint film after the droplet adheres to the surface. Since the droplet is very small and the relative surface velocity is very large, the dynamic process of the droplet morphology change can be ignored, and it can be simplified to the process of transforming a spherical droplet into a paint film with a certain uniform thickness. Paint film thickness Th 漆 With the attachment surface area S 漆 and droplet diameter d 液 The relationship is:

[0084] Th 漆 = π× (d 液 ^3) / (6×S 漆 )

[0085] Among them, the attachment surface area S 漆 It can be simplified to a constant of 1 square centimeter.

[0086] In the PC host 1, according to the user's actual operation of the switch, position, and posture of the spray simulation training device 5, the speed and flow direction of each small jet, as well as the coordinates of the contact point of each jet on the workpiece surface are calculated in real time according to the nozzle jet distribution, simulating the adhesion of small droplets of paint on the workpiece surface. Then, in the surface visual material of the simulated training painting workpiece 8, the film thickness of each pixel is stored to achieve the distribution heat map of the film thickness of the spray surface. And when the film thickness reaches or exceeds the corresponding threshold, the corresponding orange peel and sagging effects are presented through the processing of multi-layer surface visual materials, achieving the purpose of spray simulation training.

[0087] Simulate coating defects such as orange peel and sagging in the spraying online training system: record data through actual spraying experiments and establish a two-dimensional continuous mathematical model of spraying thickness and orange peel and sagging phenomena;

[0088] The physical process of the orange peel phenomenon originates from the uneven distribution of paint on the two-dimensional surface, which produces local droplets due to the uneven stress distribution under the action of surface tension. When the local droplets on the vertical surface increase and the surface tension cannot support the gravity of the droplets, sagging will occur. In the actual working process, when the thickness of the surface paint film exceeds a certain threshold, the orange peel phenomenon is likely to occur. When the degree of orange peel exceeds a certain threshold, threadhold 漆 The orange peel phenomenon is divided into the action area S 橘皮 , Local orange peel peak 橘皮 、Average local cellulite level Ave 橘皮 , the orange peel condition of the surface can be displayed and compared with the film thickness Th 漆 Make an association.

[0089] S 橘皮 =Area(Th 漆 >threadhold 漆 )

[0090] Peak 橘皮 = Max(Area(Th 漆 ))

[0091] Ave 橘皮 = Average(Area(Th 漆 ))

[0092] According to the local peak of cellulite 橘皮 Average level of local cellulite 橘皮 The deviation degree can dynamically draw the local orange peel pattern, that is, the larger the deviation degree, the more obvious the orange peel is and the stronger the bumps and depressions are.

[0093] The surface coating data is recorded in real time during the training process. When the regional data features reach or exceed the threshold, realistic orange peel and sagging effects are presented through the comprehensive use of dynamic UV mapping, dynamic roughness mapping, dynamic regional transparent mapping and other computer vision surface material processing methods.

[0094] Calculation of employee paint usage in the online spraying training system: By establishing a mathematical model for nozzle droplet distribution, a mathematical model is established for the relationship between spraying pressure, paint droplet distribution, and droplet diameter. The discrete distribution of nozzle droplets at each moment is calculated, and the total amount of paint used Q is obtained by statistical summary hour by hour. 涂料 .

[0095] Q 涂料 =∫Th 漆 ×S 漆 ×k-type 漆 ·dt

[0096] Roller coating simulation training: Change the offline roller coating training method to online training.

[0097] Through VR virtual reality simulation technology, combined with positioning technology, the posture and orientation of the hand-held roller brush are numerically restored. Combined with the mathematical model of the roller brush coating process, the simulation training program is controlled to achieve an immersive, interactive, and intuitive training experience.

[0098] The roller coating simulation training device 6 is similar in appearance to the roller brush actually used in coating. A spatial positioning terminal sensor 4 is installed at a fixed position to realize the spatial positioning function. The roller coating process itself relies on the contact between the roller brush and the workpiece surface. Therefore, only the relative relationship between its position and posture and the simulated training coating workpiece 8 is required, and the PC host 1 can calculate the coating situation of the roller coating process. The data realization of the roller coating simulation is based on the first dip empty plate full coating thickness-length test data and the second dip coating thickness-length test data in the standard roller coating experiment, and the corresponding mathematical model is established.

[0099] In the PC host 1, the surface visual material of the simulated training painting workpiece 8 stores the real-time film thickness data, and combined with the dynamic paint amount data on the roller painting simulation training device 6, the workpiece surface film thickness after roller brush painting and the new roller brush paint amount are calculated according to the mathematical model, thereby realizing the characteristics of the roller painting process, that is, the paint can be applied and the paint can be blurred. Then, in the surface visual material of the simulated training painting workpiece 8, the distribution heat map of the roller coating surface film thickness is presented to achieve the purpose of roller painting simulation training.

[0100] The technology that combines virtual roller brush with reality in the roller coating online training system: the posture and positioning values ​​of the roller brush and the workpiece are restored through positioning technology, and collision and pressure simulation are added to the simulation program to realize the function of roller brush coating the workpiece.

[0101] The core algorithm for the amount of paint applied by roller coating in the online roller coating training system: Through actual roller coating experiments, the thickness and distribution of paint applied on the workpiece surface under different paint amounts and roller coating pressures are measured to calculate the amount of paint consumed; the amount of paint applied on the workpiece surface is measured from the time the roller brush is dipped in paint until it can no longer be painted, and the total amount of paint applied by the roller brush is calculated. Finally, a complete mathematical model from the roller brush dipping to the paint applied on the workpiece surface is established. The complete mathematical model is described as follows:

[0102] The roller coating process uses a roller brush to carry paint in a paint bucket and apply it to the surface of the workpiece. Since the surface of the workpiece may also be painted, the actual amount of paint applied in each rolling coating action is related to the paint thickness of the roller brush and the paint thickness of the work surface. That is, the actual amount of paint in each action is dynamic, which may be positive or negative. Therefore, when the paint film on the surface of the workpiece is too thick, it can be spread out by applying it with a drier roller brush, thereby reducing the paint film thickness on the work surface.

[0103] The simulated physical model adopts the assumption of conservation of paint mass, that is, the paint loss due to dripping and splashing during the rolling operation is not considered; it is also assumed that the paint on the roller brush is always uniform, and the influence of ambient temperature and humidity is not considered. Assuming that the action is uniform during rolling, the thickness of the new paint film on the workpiece surface = fn_mix (the thickness of the old paint film on the workpiece surface, the thickness of the paint on the roller brush). In this way, when a dry roller brush is used to paint a thick paint surface, the thick paint on the workpiece surface will be taken away by the roller brush and become thinner. At the same time, the paint on the roller brush can be applied to other areas, realizing the thin paint application and thick paint push.

[0104] set up:

[0105] Q_brush, the amount of paint on the roller brush

[0106] K_brush, roller brush paint thickness coefficient

[0107] TH_brush, the thickness of the paint on the roller brush, TH_brush = Q_brush * K_brush, that is, the more paint on the roller brush, the thicker the paint is.

[0108] W_brush, the coating width of the roller brush, can be obtained through measurement. The actual coating width may be smaller than the roller brush width when coating at corners. The VR simulation program obtains this value through the collision width between the roller brush and the surface.

[0109] TH_surface_before, the paint film thickness of the workpiece to be rolled

[0110] Assume that, each time the roller is applied,

[0111] Delta_L: Minimum unit length of roller coating

[0112] TH_surface_after = fn * (TH_brush+TH_surface_before), the new thickness of the workpiece surface, where fn is fitted to 0.5 according to the experimental results

[0113] Delta_Q = (TH_surface_after-TH_surface_before)*W_brush * Delta_L roller paint amount

[0114] but,

[0115] Q_brush_after = Q_brush - Delta_Q, the amount of paint on the brush after rolling

[0116] Sandblasting simulation training: Change the offline sandblasting training method to online training. Through VR virtual reality simulation technology, combined with positioning technology, the posture and orientation of the handheld spray gun are numerically restored, combined with the switch signal of the sandblasting trigger to control the simulation training program, and the built-in high-speed DC fan of the spray gun is used to achieve force feedback, ultimately achieving an immersive interactive feedback-style intuitive training experience.

[0117] The recoil effect produced by simulated sandblasting in the sandblasting online training system: the high-speed DC fan is linked by a touch switch, and the airflow generated by the fan produces recoil feedback.

[0118] The sandblasting simulation training device 7 has an appearance similar to the actual nozzle used in the rust removal process. A spatial positioning terminal sensor 4 is installed at a fixed position to realize the spatial positioning function. A touch-type electronic switch is added at the nozzle trigger switch to transmit the spray switch signal back to the PC host 1. The high-speed DC fan is linked to the touch-type electronic switch at the end, and the recoil feedback is realized by the high-speed DC fan blowing to enhance the experience effect. The data realization of the sandblasting simulation first needs to be based on the principle of the occurrence and development of rust, as well as samples of rust, zinc salts, etc. of different degrees actually sampled on site, and based on the records of the actual sandblasting process, the parameters of different defect severity are restored, and a mathematical model of the distribution of rust and zinc salt defects on a two-dimensional plane is established, which is described as follows:

[0119] The distribution of defects generally starts from the joints, surface wear and local salt corrosion points, and gradually spreads to the surrounding areas, showing a diffusion pattern with a high degree at the starting point and a weakened degree around. Therefore, random rust starting points can be set at the joints and the surface, and random erosion time can be set at each point to obtain the rust degree of each random rust starting point. Then, according to the characteristics of the outward diffusion of the starting point, the rust is diffused on the surface to the surrounding areas to obtain the rust distribution.

[0120] Secondly, it is necessary to record the surface state of the workpiece after different nozzle pressures and blasting times in the actual sandblasting and rust removal process to realize the mathematical model of the rust removal process, which is described as follows:

[0121] The sandblasting rust removal process can be regarded as the reverse process of the spraying process.

[0122] Rust removal thickness delta 锈 With blasting pressure P 喷砂 , Sand material rust removal coefficient k 喷砂 The relationship is as follows:

[0123] delta 锈 =P 喷砂 ×k 喷砂

[0124] Surface rust thickness Th 锈 Derusting thickness delta锈 The relationship is:

[0125] Th 锈 = Th 锈-初始 - Min(Th 锈-初始 , ∫delta 锈 ·dt)

[0126] In the PC host 1, according to the input set rust degree, based on the defect mathematical model and the rust surface area, a defect distribution heat map is generated, and combined with computer visual surface material processing methods such as dynamic UV mapping, dynamic roughness mapping, and dynamic area transparent mapping, realistic rust and zinc salt effects are presented, and the rust data is recorded in the surface visual material; then according to the user's actual operation of the switch, position, and posture of the sandblasting simulation training device 7, according to the nozzle jet distribution, the speed and flow direction of each small jet, as well as the contact point coordinates of each jet on the workpiece surface are calculated in real time to simulate the collision and rust removal process of the sandblasting jet on the workpiece surface. Finally, in the surface visual material of the simulated training painted workpiece 8, and based on the rust residue data and paint residue data, the visual appearance of the workpiece surface after sandblasting is calculated to achieve the purpose of sandblasting simulation training.

[0127] In the sandblasting online training system, the steel plate surface randomly generates rust and zinc salts that need to be treated: according to the principle of rust occurrence and development, as well as samples of rust, zinc salts and other samples of different degrees actually sampled on site, and according to the records of the actual sandblasting process, the parameters of different defect severity are restored, and a mathematical model of the distribution of rust and zinc salt defects on a two-dimensional plane is established. During the simulation, according to the input set rust degree, based on the mathematical model and the rust surface area, a defect distribution heat map is generated, and combined with computer vision surface material processing methods such as dynamic UV mapping, dynamic roughness mapping, and dynamic area transparent mapping, realistic rust and zinc salt effects are presented.

[0128] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. The ship green painting simulation training system is characterized by: The system includes a PC host, a VR head-mounted experience device, a space positioning base station, a space positioning terminal sensor, a spraying simulation training device, a roller coating simulation training device, a sandblasting simulation training device, and a simulated training coating workpiece; The space positioning base station is fixedly installed at a high place in the training environment, and emits modulated invisible laser into the space to realize the space positioning lighthouse function; The spatial positioning terminal sensor is installed at a fixed position of a spraying simulation training device, a roller coating simulation training device, a sandblasting simulation training device and a simulated training coating workpiece, and receives a modulated laser signal from a spatial positioning base station to calculate its relative position and posture data with the spatial positioning base station in real time, thereby realizing the digitization of its position and posture, and transmitting the data to a VR virtual reality head-mounted experience device via a Bluetooth signal, and finally connecting it to a PC host to realize the positioning and posture functions of each component of the system; The VR virtual reality head-mounted experience device receives the signal of the space positioning base station, calculates its position and posture in space, and connects the data to the PC host. According to its position and posture in space, the PC host calculates the position and posture of each component in real time, and transmits the picture that the VR virtual reality head-mounted experience device needs to present back in real time, so that the user can finally watch and act freely in the virtual scene in an immersive training site environment through the VR virtual reality head-mounted experience device, and operate the spraying simulation training device, the roller coating simulation training device, and the sandblasting simulation training device to perform relevant training subjects on the simulated training painting workpiece; The appearance of the spray simulation training device is similar to the spray gun actually used for painting. A spatial positioning terminal sensor is installed at a fixed position to realize the spatial positioning function. A touch-type electronic switch is added at the spray trigger switch to transmit the spray switch signal back to the PC host. The data of the spray simulation is realized based on the relationship between the nozzle pressure and the jet morphology, the effective spray distance, the distribution of the coating thickness of one spray, and the distribution of the coating thickness of multiple sprays obtained in the standard spray experiment, and a corresponding mathematical model is established. In the PC host, according to the switch, position, and posture of the spray simulation training device actually operated by the user, and according to the nozzle jet distribution, the speed and flow direction of each small jet and the coordinates of the contact point of each jet on the surface of the workpiece are calculated in real time to simulate the adhesion of small droplets of paint on the surface of the workpiece. Then, in the surface visual material of the simulated training painting workpiece, the film thickness of each pixel is stored to realize the distribution heat map of the film thickness of the spray surface; and when the film thickness reaches or exceeds the corresponding threshold, the corresponding orange peel and sagging effects are presented. The appearance of the roller coating simulation training device is similar to the roller brush actually used for painting. A spatial positioning terminal sensor is installed at a fixed position to realize the spatial positioning function. According to the relative relationship between the position and posture of the roller coating simulation training device and the simulated training painting workpiece, the coating situation of the roller coating process is calculated; the roller coating simulation data is established based on the full coating thickness-length test data of the empty plate with one dip and the coating thickness-length test data of the second dip in the standard roller coating experiment; in the PC host, the real-time coating thickness data is stored in the surface visual material of the simulated training painting workpiece, and the dynamic paint amount data on the roller coating simulation training device is combined to calculate the surface coating thickness of the workpiece after the roller brush is applied and the new roller brush paint amount, and finally establish a complete mathematical model from roller brush dipping to application to the workpiece surface; then, in the surface visual material of the simulated training painting workpiece, a distribution heat map of the coating surface thickness is presented; The appearance of the sandblasting simulation training device is similar to the actual nozzle used in the rust removal process. A spatial positioning terminal sensor is installed at a fixed position to realize the spatial positioning function. A touch-type electronic switch is added at the nozzle trigger switch to transmit the spray switch signal back to the PC host. The high-speed DC fan is linked with the touch-type electronic switch at the end, and the recoil feedback is realized by blowing air through the high-speed DC fan. The data of the sandblasting simulation is realized according to the principle of rust occurrence and development and the different degrees of rust and zinc salt samples actually sampled on site, and according to the records of the actual sandblasting process, the parameters of different defect severity are restored, and the mathematical model of the distribution of rust and zinc salt defects on a two-dimensional plane is established. Then, according to the actual sandblasting rust removal process, the surface state of the workpiece after different nozzle pressures and sandblasting times is recorded to realize the mathematical model of the rust removal process. In the PC host, according to the input set rust degree and based on the rust surface area, a defect distribution heat map is generated, and combined with the computer vision surface material processing methods of dynamic UV mapping, dynamic roughness mapping, and dynamic area transparent mapping, the rust and zinc salt effects are presented and the rust data is recorded in the surface visual material; then according to the user's actual operation of the switch, position, and posture of the sandblasting simulation training device, according to the nozzle jet distribution, the speed and flow direction of each small jet, as well as the contact point coordinates of each jet on the workpiece surface are calculated in real time to simulate the collision and rust removal process of the sandblasting jet on the workpiece surface; finally, in the simulated training painted workpiece surface visual material, and based on the rust residue data and paint residue data, the visual appearance of the workpiece surface after sandblasting is calculated.

2. The ship green painting simulation training system according to claim 1 is characterized by: The data realization of spray simulation is based on the relationship between nozzle pressure and jet morphology, effective spray distance, one-time spray coating thickness distribution, and multiple-time spray coating thickness distribution obtained in the standard spray experiment. The corresponding mathematical model is established as follows: In the mathematical model, the physical process is divided into three stages: pressure squeezes the droplets to the nozzle to diffuse and form droplets, the droplets jet in the air, and the droplets adhere to different surfaces to form a paint film; When the pressure squeezes the droplet to the nozzle and diffuses to form a droplet, the droplet diameter d 液 With pressure P, nozzle type T-type 喷嘴 , paint type coefficient k-type 油漆 Simplified to d 液 =K-type 油漆 / (P × T-type 喷嘴 ) When a droplet is jetting in the air, the initial velocity v of the droplet in the air is 液 With pressure P, nozzle type T-type 喷嘴 , the speed coefficient kv relationship is: v 液 =P × T-type 喷嘴 × kv The process of forming a paint film after the droplet adheres to the surface can be simplified as the process of transforming a quasi-spherical droplet into a paint film with a certain uniform thickness; the paint film thickness Th 漆 With the attachment surface area S 漆 and droplet diameter d 液 The relationship is: Th 漆 = π× (d 液 3 ) / (6×S 漆 ) Among them, the attachment surface area S 漆 Simplified to a constant of 1 square centimeter.

3. The ship green painting simulation training system according to claim 1 is characterized by: The calculation of the amount of paint used in the spray simulation training device is as follows: by establishing a mathematical model of nozzle droplet distribution, a mathematical model is established for the relationship between spray pressure, paint droplet distribution, and droplet diameter, the discrete distribution amount of nozzle droplets at each moment is calculated, and the total amount of paint used Q is obtained by statistical summary hour by hour. 涂料 ; Q 涂料 =∫Th 漆 ×S 漆 ×k-type 漆 ·dt Th 漆 is the film thickness, S 漆 is the attachment surface area, k-type 油漆 is the paint type coefficient.

4. The ship green painting simulation training system according to claim 1 is characterized by: When the coating thickness reaches or exceeds the corresponding threshold, the corresponding orange peel and sagging effects are presented, specifically: Through actual spraying experiments, data is recorded and a two-dimensional continuous mathematical model of spraying thickness, orange peel and sagging phenomena is established. When the surface paint film thickness exceeds a certain threshold, orange peel phenomenon occurs. When the degree of orange peel exceeds a certain threshold, threadhold 漆 When the flow phenomenon occurs; The cellulite phenomenon is divided into the action area S 橘皮 , Local orange peel peak 橘皮 、Average local cellulite level Ave 橘皮 , the orange peel condition of the surface can be displayed and compared with the film thickness Th 漆 Make associations; S 橘皮 =Area(Th 漆 >threadhold 漆 ) Peak 橘皮 = Max(Area(Th 漆 )) Ave 橘皮 = Average(Area(Th 漆 )) According to the local peak of cellulite 橘皮 Average level of local cellulite 橘皮 The deviation degree is used to dynamically draw the local orange peel pattern. That is, the larger the deviation degree, the more obvious the orange peel is and the stronger the bumps are.

5. The ship green painting simulation training system according to claim 1 is characterized by: A complete mathematical model is established from rolling brush dipping to applying to the workpiece surface. The specific process is as follows: The simulated physical model adopts the assumption of conservation of paint mass, and also assumes that the paint on the roller brush is always uniform and the action of rolling is uniform. Then the thickness of the new paint film on the workpiece surface = fn_mix (the thickness of the old paint film on the workpiece surface, the thickness of the paint on the roller brush); Calculation of roller brush paint thickness: TH_brush = Q_brush × K_brush Among them, TH_brush is the thickness of the paint on the roller brush, Q_brush is the amount of paint on the roller brush, and K_brush is the thickness coefficient of the paint on the roller brush; that is, the more paint on the roller brush, the thicker the paint thickness will be; Calculation of the amount of paint applied by roller coating: Delta_Q = (TH_surface_after-TH_surface_before) ×W_brush × Delta_L Among them, W_brush is the coating width of the roller brush, TH_surface_before is the paint film thickness of the surface workpiece to be coated, and Delta_L is the minimum unit length of coating; Each time the roller coating is applied, the new thickness of the workpiece surface TH_surface_after is: TH_surface_after = fn× (TH_brush+TH_surface_before), where fn is fitted to 0.5 according to experimental results; The amount of paint on the roller brush after rolling Q_brush_after Q_brush_after= Q_brush - Delta_Q.

6. The ship green painting simulation training system according to claim 1 is characterized by: A mathematical model of the distribution of rust and zinc salt defects on a two-dimensional plane is established. Specifically, random rust starting points are set at the joints and on the surface, and a random erosion time is set at each point to obtain the degree of rust at each random rust starting point. Then, according to the outward diffusion characteristics of the starting point, the rust is diffused around the surface to obtain the distribution of rust and zinc salt defects.

7. The ship green painting simulation training system according to claim 1 is characterized by: According to the actual sandblasting and rust removal process, the surface state of the workpiece after different nozzle pressures and sandblasting time is recorded to realize the mathematical model of the rust removal process, which is as follows: The sandblasting rust removal process is regarded as the reverse process of the spraying process. The rust removal thickness delta 锈 With blasting pressure P 喷砂 , Sand material rust removal coefficient k 喷砂 The relationship is as follows: delta 锈 = P 喷砂 ×k 喷砂 Surface rust thickness Th 锈 Derusting thickness delta 锈 The relationship is: Th 锈 = Th 锈-初始 - Min(Th 锈-初始 ,∫delta 锈 ·dt)。

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