Sealing operation automation system using robot and method thereof

Abstract

The present invention relates to a sealing operation automation system using a robot and a method thereof, the system comprising: a robot configured to perform a brushing operation of spreading a sealant applied to a seam by moving a brushing operation tool to an operation position at a lower part of a vehicle body; a three-dimensional (3D) sensor mounted on the robot and configured to photograph a work area of the seam to acquire 3D data; a residual sealant remover configured to remove the residual sealant by applying a physical force to a brush of the brushing work tool that is contaminated after the brushing work; a robot path generator configured to generate a robot path for a brushing operation by matching the 3D data received from the 3D sensor with design data for the brushing operation of the seam; and a robot controller configured to control the overall operation of the robot and control the brushing operation of the robot based on the robot path.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of Korean Patent Application No. 10-2023-0116039, filed on September 1, 2023, which is incorporated herein by reference. Technical Field

[0003] The invention relates to a sealing operation automation system using a robot and a method thereof. Background Art

[0004] Generally speaking, in a vehicle sealing factory, a large number of parts are undergoing sealing operations, that is, applying sealants to the joints of the lower part of the assembled vehicle body. The sealing operation is for water tightness and to reduce the vibration and noise of the lower part of the vehicle body. In the prior art, it is performed manually, and workers use brushes to apply sealants along the joints.

[0005] However, the sealing work in the prior art has problems in that sealant slippage and sealant holes are caused based on the skill level of the workers, and poor quality is caused due to human errors such as poor brush mark surface. In addition, due to the nature of the work being performed on the underbody, the workers must look up and perform repetitive brushing work, which can cause high musculoskeletal fatigue and cause injuries. Therefore, a method of automating the sealant brushing work on the underbody is needed.

[0006] The above information disclosed in this Background section is only for enhancement of understanding of the background of the embodiments of the present invention and therefore it contains information that does not constitute known prior art. Summary of the invention

[0007] The present invention relates to a sealing operation automation system and method using a robot. A specific embodiment relates to a sealing operation automation system and method for applying a sealant on a lower part of a vehicle body.

[0008] An exemplary embodiment of the present invention is directed to providing a sealing work automation system and method using a robot, which uses a robot equipped with a brush working tool to perform a brushing work of applying sealant to a joint of a vehicle body, and at the same time, automates the residual sealant removal, brush status inspection and old brush replacement operations to maintain the brush status, thereby providing accurate and uniform sealant finishing quality.

[0009] An exemplary embodiment of the present invention provides a sealing operation automation system using a robot, including: a robot, which performs a brushing operation to spread a sealant applied to a joint by moving a brushing operation tool to a lower part of a vehicle body; a 3D sensor, which is installed on the robot and photographs a working area of ​​the joint to acquire 3D data; a residual sealant remover, which removes residual sealant by applying physical force to a brush of the brushing operation tool that is contaminated after the brushing operation; a robot path generator, which generates a brushing operation robot path by matching the 3D data received from the 3D sensor with design data of the brushing operation of the joint; and a robot controller, which controls the overall operation of the robot and controls the robot's brushing operation based on the robot path.

[0010] In addition, the brush painting tool includes: a brush, which is composed of bristles having a flat shape at the front and a brush handle extending from the bristles in the longitudinal direction; a main changer, which is attached to the robot and includes a first magnet at the lower part; and a sub-changer, which, when the brush is combined with the clamp, uses a second magnet configured at the upper part and is installed on or separated from the main changer through a wireless switching scheme.

[0011] In addition, the 3D sensor scans the working area through a 3D scanning camera capable of recognizing depth to generate 3D data; and transmits the generated 3D data to the robot path generator to recognize the shape of the working area and the joints to which the sealant is to be applied.

[0012] In addition, the robot can control the scanning angle of the 3D sensor by rotating the end effector according to the working area; and control the angle of the flat brush relative to the brushing direction of the joint by rotating the end effector during brushing operations.

[0013] In addition, the residual sealant remover may include: a first sealant removal module, which is configured with a rod horizontally fixed to the inner wall of a shell with a top opening, which moves horizontally to preliminarily remove the residual sealant that physically contacts the brush; and a second sealant removal module, which secondary removes the sealant and restores the brush shape by physically pressing the front and back of the brush using polyurethane blocks facing each other in a horizontal direction while raising the brush working tool.

[0014] In addition, the second sealant removal module includes: a plurality of urethane blocks facing each other in a downwardly inclined cone shape; movable bodies respectively coupled to the urethane blocks and moving left and right; and an actuator driving the urethane blocks in opposite directions through screws connected to the respective movable bodies.

[0015] In addition, the sealing operation automation system also includes: a brush inspector, which takes front and side images of the brush from which the residual sealant has been removed to determine whether the brush status is normal or defective (OK / NG) based on image sensing; and a tool changer, which recovers the brush painting tool of the brush judged to be defective (NG) from the robot and provides a new brush painting tool to replace the existing brush painting tool.

[0016] In addition, the brush inspector includes: a box with an opening at the top to form a box-shaped space; a first camera installed on the vertical side of the box to capture a front image of the brush located at the center; a first backlight installed on the vertical side of the box to emit light from the rear surface of the brush; a second camera to capture a side image of the brush; and a second backlight to emit light from the other side of the brush.

[0017] In addition, the first camera and the second camera can use the brightness difference of the backlight to measure the number of pixels and the brush area of ​​the brush in each captured image; and judge whether the brush status is normal (OK / NG) based on whether the number of pixels and the brush area meet the set reference values ​​for each of the multiple divided sensing areas in each image.

[0018] In addition, when all of the following conditions are met, the first camera and the second camera can judge that the brush state is normal: the first condition, the brush state is judged to be normal when the brush area is within the allowed sensing area; the second condition, the brush state is judged to be normal when only one brush area is detected in any sensing area; the third condition, the brush state is judged to be normal when the number of pixels of the brush area of ​​each sensing area meets the set reference value.

[0019] In addition, the tool changer includes: a plurality of tool holders horizontally arranged in a T-shaped support member and forming a base structure for the painting tool; and a proximity sensor, detecting whether the painting tool is located on each tool holder and transmitting whether the painting tool is located on each tool holder to the robot controller.

[0020] In addition, the robot path generator can generate a 3D model, which uses a visual program to set the robot path required for the painting operation on the car body through the preset operation of the painting operation; calculates the correction value according to the matching error generated by preprocessing the 3D data received in the actual painting operation; matches the 3D model; displays the predefined robot path in the working area of ​​the 3D data; and corrects the coordinates of the robot path according to the position of the working area of ​​the car body.

[0021] In addition, the robot path generator can provide a graphical user interface (GUI) that simplifies the user (engineer) modification of the robot path by using offline programming (OLP); the teaching points in the 3D data can be exported using the GUI; and precise teaching and robot path modification functions are provided for each work area required by the user.

[0022] In addition, the robot path generator can form the normal coordinate value of a specific point or expected position of the working seat surface of the main watertight part of the car body through the GUI; and modify at least one of the teaching point angle, brush depth or brush rotation angle based on the normal coordinate value to support precise control that imitates the painting skills of skilled workers.

[0023] In addition, the robot controller can generate a control signal based on the robot path received from the robot path generator to control the robot's brushing operation; and control at least one operation of the robot's residual sealant removal mode, brush status inspection mode or tool replacement mode to maintain the brush status after the brushing operation is completed.

[0024] Meanwhile, another exemplary embodiment of the present invention provides a method for automating sealing work using a robot, comprising the following steps: moving a brushing work tool and a 3D sensor mounted on the robot to a working position on the lower part of a vehicle body, and photographing a working area of ​​a joint by means of the 3D sensor to acquire 3D data; generating a robot path by matching the 3D data with a 3D model of a brushing work for the joint; controlling a brushing work to spread the sealant applied to the joint by moving the brushing work tool along the robot path; moving the brushing work tool to a residual sealant remover to remove residual sealant stained in a brush of the brushing work tool, and restoring the shape of the brush after the brushing work is completed; photographing a front image and a side image of the brush by a brush inspector to determine whether the brush state is normal (OK / NG) based on image sensing; and when the brush state is determined to be defective (NG), moving the defective brushing work tool to a tool replacer, separating the brushing work tool by a magnetic scheme, and then replacing the brushing work tool with a new brushing work tool, and installing the new brushing work tool.

[0025] In addition, generating a robot path includes the following steps: preliminarily setting the job, generating a 3D model using a visual program, which sets the robot path required for the painting operation of the car body; performing a preprocessing job, extracting the working area area from the 3D data and removing unnecessary data in the painting operation; matching the 3D model corresponding to the preprocessed 3D data in 3D to calculate a correction value based on the generation of a matching error; and displaying the predefined robot path in the working area area of ​​the 3D data, and correcting the coordinates of the robot path according to the position of the working area area of ​​the car body.

[0026] In addition, the step of removing the residual sealant and restoring the shape of the brush includes: preliminarily removing the residual sealant stained in the brush by physically contacting the brush with the horizontal fixing rod of the first sealant removal module; and secondarily removing the residual sealant and restoring the shape of the brush by raising the operation of the brush painting working tool while physically pressing the front and back sides of the brush using polyurethane blocks facing each other in the horizontal direction of the second sealant removal module.

[0027] In addition, in judging whether the brush state is normal (OK / NG), the number of pixels and the brush area of ​​the brush are measured for each of the front image and the side image, and whether the brush state is normal (OK / NG) is judged based on whether the number of pixels and the brush area meet the set reference value of each of the multiple divided sensing areas in the image; and when all of the following conditions are met, the brush state can be judged to be normal: the first condition, the brush state is judged to be normal when the brush area is within the allowed sensing area; the second condition, the brush state is judged to be normal when only one brush area is detected in any sensing area; the third condition, the brush state is judged to be normal when the number of pixels of the brush area of ​​each sensing area meets the set reference value.

[0028] In addition, the steps of replacing and installing may include: moving the robot to an empty tool replacer; installing the defective painting tool to the empty first tool holder / separating the defective painting tool from the empty first tool holder; moving the robot to the second tool holder; installing a new painting tool; and returning the robot to its original position.

[0029] According to an exemplary embodiment of the present invention, the following effects are achieved: by installing a brushing operation tool optimized for the brushing operation of the sealant on a robot and using a 3D sensor to reduce the existing manual work manpower and to make the sealant finishing quality uniform, a precise brushing operation is controlled by a corrected robot path.

[0030] Furthermore, there is an effect that the removal of residual sealant stained on the brush, the brush condition inspection, and the replacement and installation process of old brush painting work tools are automated, thereby maintaining the shape of the brush in a state optimized for brush painting work.

[0031] Furthermore, the effect of using a tool changer using switch magnetic technology to wirelessly and automatically change brush work tools to reduce replacement time and improve processing operation efficiency can be expected. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 is a schematic diagram schematically illustrating a sealing operation automation system according to an exemplary embodiment of the present invention;

[0033] Figure 2 A brush painting tool and a replacement structure according to an exemplary embodiment of the present invention are shown;

[0034] Figure 3 shows the construction of a residual sealant remover according to an exemplary embodiment of the present invention;

[0035] Figure 4 shows the construction of a brush inspector according to an exemplary embodiment of the present invention;

[0036] Figure 5 A method for determining whether a brush inspector is defective according to an exemplary embodiment of the present invention is shown;

[0037] Figure 6 shows the construction of a tool changer according to an exemplary embodiment of the present invention;

[0038] Figure 7 is a schematic diagram illustrating a method for generating a robot path for a sealing operation according to an exemplary embodiment of the present invention;

[0039] Figure 8 A teaching condition database (DB) construction method using an OLP-based GUI according to an exemplary embodiment of the present invention is shown;

[0040] Fig. 9 FIG. 4 is a flow chart schematically illustrating a sealing operation automation method according to an exemplary embodiment of the present invention.

[0041] Description of Reference Numerals :

[0042] 10: Body

[0043] 20a / 20b: Sealant (coating / contamination)

[0044] 100: Sealing operation automation system

[0045] 110: Brush painting tools

[0046] 111: Brush

[0047] 1111: Brush

[0048] 1112: Brush handle

[0049] 112: Tool Changer

[0050] 1121: Master Changer

[0051] 1122: Vice Changer

[0052] 1123a, 1123b: first and second magnets

[0053] 1124: Gripper

[0054] 120: 3D sensor

[0055] 130: Robot

[0056] 131: End effector

[0057] 140: Residual sealant remover

[0058] 141: First sealant removal module

[0059] 1411: Shell

[0060] 1412: Rod

[0061] 142: Second sealant removal module

[0062] 1421a, 1422b: Polyurethane blocks

[0063] 1422a, 1422b: Movable body

[0064] 1423a, 1423b: Screws

[0065] 1424: Actuator

[0066] 150: Brush Inspector

[0067] 151a, 152a: first and second cameras

[0068] 151b, 152b: first and second backlight

[0069] 153: Box

[0070] 154: Space

[0071] 160: Tool Replacer

[0072] 161: Support

[0073] 162: Tool holder

[0074] 163: Proximity sensor

[0075] 170: Control System

[0076] 171: Robot Path Generator

[0077] 172: Robot Controller

[0078] 173: GUI. DETAILED DESCRIPTION

[0079] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily realize it.

[0080] The terms used herein are only used to describe specific exemplary embodiments and are not intended to limit the present invention. As used herein, singular forms are also intended to include plural forms, unless the context clearly indicates them differently. It should be understood that when the terms "include" and / or "include" are used in this specification, the terms "include" and / or "include" are intended to specify the existence of the features, integers, steps, operations, constituent elements and / or parts mentioned, but they do not exclude the existence or addition of one or more other features, integers, operations, constituent elements, parts or their groups. The term "and / or" used herein includes any or all combinations of associated and listed items.

[0081] Throughout the specification, terms including first, second, A, B, etc. are used to describe various constituent elements, but the constituent elements are not limited by these terms. These terms are only intended to distinguish components from other components, and these terms do not limit the nature, order or sequence of the components.

[0082] It should be understood that when a component is described as being "connected" or "close to" another component, the component may be directly connected or close to the other component, or a third component may exist therebetween throughout the specification. Conversely, it should be understood that when a component is described as being "directly connected to" or "directly close to" another component, it should be understood that there is no element between the element and the other element.

[0083] Throughout the specification, the terms are used only to describe specific exemplary embodiments and are not intended to limit the present invention. A singular expression includes a plural expression if there is no clear contrary meaning in the context.

[0084] In addition, it should be understood that at least one of the following methods or aspects thereof or one or more of the aspects may be performed by one or more controllers. The term "controller" may refer to a hardware device including a memory and a processor. The memory is configured to store program instructions, and the processor is specifically programmed to execute program instructions to perform one or more processes described in more detail below. As disclosed herein, a controller may control the operation of a unit, module, part, device, or those units, modules, parts, devices similar thereto. In addition, as recognized by those skilled in the art, it should be understood that the following methods may be performed by a device including a controller in conjunction with one or more other components.

[0085] Hereinafter, a sealing work automation system using a robot and a method thereof according to an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0086] Figure 1 A sealing work automation system using a robot according to an exemplary embodiment of the present invention is schematically illustrated.

[0087] Figure 2 A painting working tool and a replacement structure according to an exemplary embodiment of the present invention are shown.

[0088] refer to Figure 1 and 2 , a sealing work automation system 100 using a robot according to an exemplary embodiment of the present invention includes: a robot 130, which spreads the sealant 20a applied to the joint by the brushing work tool by moving the brushing work tool 110 to the lower part of the vehicle body 10; a 3D sensor 120, which is installed on the robot 130 and acquires 3D data by scanning a designated joint work area; a residual sealant remover 140, which removes the residual sealant by applying a physical force to the contaminated brush 111 after the brushing work; and a brush inspector 150, which photographs the residual sealant removed. Front and side images of the brush 111, and determining whether the brush status is normal (OK / NG) based on image sensing; a tool replacer 160, after checking the brush, replaces the existing painting tool 110 determined to be NG with a new painting tool 110; a robot path generator 171, matches the 3D data received from the 3D sensor 120 with the design data for the painting operation of the joint, and generates a robot path for the painting operation; a robot controller 172, controls the overall operation of the robot 130 for the painting operation based on the robot path.

[0089] The painting work tool 110 and the 3D sensor 120 are installed to be rotatable around the end effector 131 of the multi-joint robot 130. The robot 130 can ensure the degree of freedom of precise painting work of the painting work tool 110 having 7 or more axes.

[0090] In an embodiment of the present invention, the brushing automation refers to a sealing finishing operation in which the robot 130 brushes by moving the brush 111 of the brushing tool 110 to evenly spread the sealant 20a and precisely seal the joint portion while applying the sealant 20a to the joint.

[0091] Therefore, the sealing operation automation system 100 includes a brush 111 optimized for brushing, which is made of sealant 20a so as to implement precise and uniform quality brushing operations through the robot 130, and is intended to provide maintenance and replacement management of the brush status, robot teaching including robot paths, and complex robot control based thereon.

[0092] The painting tool 110 includes a brush 111 and a tool changer 112 .

[0093] The brush 111 is composed of bristles 1111 having flat front portions and a brush handle 1112 extending from the bristles 1111 in a longitudinal direction.

[0094] The bristles 1111 may be composed of acrylic artificial hair, which is optimized for brushing automation by comprehensively considering the compressibility of the sealant, brushing uniformity, brushing quality, durability and unit price compared to existing pig hair, wool and silicone hera. The bristles 1111 are the core component of the brush 111 and basically represent the symbol and characteristics of the brush 111 itself. Therefore, hereinafter, as long as there is no separate description throughout the specification, the brush 111 should be understood to basically refer to or mean the bristles 1111.

[0095] The tool changer 112 includes: a main changer 1121, which is attached to the robot 130 and has a first magnet 1123a at the lower part; and a sub-changer 1122, which is installed on the main changer 1121 (ON) or separated from the main changer 1121 (OFF) through a wireless switching scheme using a second magnet 1123b, and the second magnet is configured at the upper part when combined with the brush 111 through the clamp 1124.

[0096] The first magnet 1123a and the second magnet 1123b may be collectively referred to as magnets 1123 and may be attached / detached by an electrical switch signal (ON / OFF). The holder 1124 may fasten and couple the brush handle 1112 by a coupling member such as a screw / bolt when the brush handle 1112 is inserted into the inner space.

[0097] The 3D sensor 120 scans the working area through a 3D scanning camera capable of recognizing depth to generate 3D data. The 3D sensor 120 transmits the generated 3D data to the robot path generator 171 to recognize the shape of the working area and the joint to which the sealant 20a is to be applied.

[0098] The robot 130 rotates the end effector 131 according to the working area to control the scanning (shooting) angle of the 3D sensor 120. In addition, the robot 130 rotates the end effector 131 during the painting operation to control the angle of the flat brush 111 according to the painting direction of the joint.

[0099] The robot 130 is controlled by the mechanical motion (also referred to as posture control) of the robot controller 172 to move the painting tool 110 to a designated joint position to perform the painting work.

[0100] At the same time, the maintenance and replacement management system of the brush status is described.

[0101] When the brushing work of the designated joint is completed, the robot 130 moves the brushing work tool 110 to the residual sealant remover 140 to remove the residual sealant 20 b stained in the brush 111 and restore the shape of the brush 111 .

[0102] Figure 3 The configuration of a residual sealant remover according to an exemplary embodiment of the present invention is shown.

[0103] refer to Figure 3 , a residual sealant remover 140 according to an exemplary embodiment of the present invention includes a first sealant removing module 141 and a second sealant removing module 142 which continuously remove the residual sealant 20b of the brush 111 contaminated by the residual sealant 20b after a brushing operation.

[0104] The first sealant removal module 141 is provided with a rod 1412 which is horizontally fixed to the inner wall of the housing 1411 whose top surface is opened and moves horizontally, and preliminarily removes a large piece of residual sealant 20b which physically contacts the brush 111. In this embodiment, the robot 130 reciprocates in a first direction (e.g., right) and a second direction (e.g., left) in a posture of tilting the brush working tool 110 toward the rod 1412 at a predetermined angle to remove the residual sealant 20b attached to the front and back surfaces of the brush 111. The removed residual sealant 20b falls to the floor due to gravity.

[0105] The second sealant removing module 142 secondarily removes the sealant and restores the brush shape by raising the brush working tool while physically pressing the flat front and back sides of the brush using a pair of urethane blocks 1421a and 1421b facing each other in a horizontal direction.

[0106] The second sealant removal module 142 includes: a plurality of polyurethane blocks 1421a and 1421b facing each other in a downwardly inclined conical shape; movable bodies 1422a and 1422b respectively coupled to the polyurethane blocks 1421a and 1421b and moving left and right; and an actuator 1424 driving the polyurethane blocks 1421a and 1421b in opposite directions by screws 1423a and 1423b respectively connected to the movable bodies 1422a and 1422b.

[0107] The second sealant removal module 142 usually waits in a state where the polyurethane blocks 1421a and 1421b are moved outward and opened, and when the brush 111 is lowered by the brushing operation tool 110, the second sealant removal module 142 moves the polyurethane blocks 1421a and 1421b inward and presses the front and back sides of the brush 111 at a predetermined interval. In this embodiment, the robot 130 raises the brushing operation tool 110 to remove the residual sealant 20b for the second time and restore the shape of the brush 111 by contact with the polyurethane blocks 1421a and 1421b. Thereafter, the second sealant removal module 142 returns the polyurethane blocks 1421a and 1421b to the waiting state.

[0108] The residual sealant remover 140 has an advantage in that it can physically remove the sealant having stickiness from the brush 111 without using a cleaning device that cleans the brush by using a cleaning solution as in the related art, while maintaining the shape of the brush in a shape optimized for brushing work.

[0109] at the same time, Figure 4 The configuration of a brush inspector according to an exemplary embodiment of the present invention is shown.

[0110] Figure 5 A method for determining whether a brush inspector is defective according to an exemplary embodiment of the present invention is shown.

[0111] refer to Figure 4 and 5 When the residual sealant removal work is completed, the robot 130 may check the state of the brush 111 by moving the brush working tool 110 to the center C of the brush checker 150 .

[0112] The brush inspector 150 includes: a box 153, the top of which is open to form a box-shaped space 154; a first camera 151a for capturing a front image of a brush 111 located in the center and a first backlight 151b for emitting light on the back side of the brush 111, which are respectively installed on the vertical sides of the box 153; and a second camera 152a for capturing a side image of the brush 111 and a second backlight 152b for emitting light on the other side of the brush 111.

[0113] The first camera 151a and the second camera 152a can respectively measure the number of pixels and the brush area (i.e., pixel area) of the brush by using the brightness difference caused by the backlight 152b in the captured image, and judge whether the brush state is normal (OK / NG) according to whether the number of pixels and the brush area meet the reference value of each of multiple divided sensing areas in the image.

[0114] For example, refer to Figure 5, the front image and the side image displayed in the first camera 151a and the second camera 152a can be respectively set as the sensing area and the reference value condition divided for checking the brush state, and the brush area (brush image) is represented by a dark color due to the backlight 151b and 152b.

[0115] The first camera 151a and the second camera 152a determine the brush area and the number of pixels thereof in each sensing region set in each image, and judge the brush state by comparing the brush area and the number of pixels with reference value conditions.

[0116] The first camera 151a and the second camera 152a have a first condition for judging that the brush state is normal (OK) when the brush area is located within the sensing permission area.

[0117] If there are a total of 6 sensing areas in the front image of the brush 111, and the allowed sensing areas are defined as ①, ②, and ③, when the brush area is located in the allowed sensing area, the brush state can be judged to be normal (OK). Accordingly, when the brush area deviates from the allowed sensing area (or when the brush area is sensed to be located in the non-allowed sensing area), it is recognized that the brush is damaged or contaminated, and the brush state is judged to be defective (NG).

[0118] In addition, under the second condition that only one brush area is detected in one sensing area, it is possible to judge whether the brush state is normal (OK / NG). Since there is only one brush area for the brush image in each of ①, ②, and ③ relative to the normal image of the front image, the brush state can be judged to be normal (OK). On the contrary, when two or more brush areas are sensed in one sensing area, like "A", it is recognized that the brush is separated, thereby judging the brush state to be defective (NG).

[0119] In addition, as in the inspection example of the side image of the brush 111, when the number of pixels of the brush area of ​​each sensing area meets the set reference value, the brush state is judged to be normal (OK). Conversely, when the number of pixels of the brush image of the sensing area ① is greater than the set reference value, like "B", the brush state can be judged to be defective (NG) by recognizing that the area is increased due to sealant contamination.

[0120] The above inspection example is not limited to the front image and the side image, and is applied to both the first camera 151a and the second camera 152a, and when all conditions are met, the brush state can be judged to be normal, and the judgment result can be transmitted to the robot controller 172. However, when the brush inspection judgment result is defective (NG), the brush inspector 150 can display the brush inspection judgment result through a warning light.

[0121] at the same time, Figure 6 The configuration of a tool changer according to an exemplary embodiment of the present invention is shown.

[0122] refer to Figure 6 The tool changer 160 includes: a plurality of tool holders 162, which are horizontally arranged in a T-shaped support member 161 and form a base structure for the painting tool 110; and a proximity sensor 163, which senses whether the painting tool 110 is in place (ON / OFF) for each tool holder 162, and transmits the information to the robot controller 172. Figure 6 In the figure, for the convenience of description, it is assumed that there are two tool holders 162, but the number of tool holders is not limited thereto, and further tool holders 162 may be provided.

[0123] When the brush state is determined to be defective (NG) due to the execution of the above-mentioned brush inspection, the robot 130 moves to the tool changer 160 to separate the existing brush painting tool 110 from the empty first tool holder 162-1, moves to the second tool holder 162-2 to install the new brush painting tool 110, and returns to the original position. In this embodiment, the existing brush painting tool 110 and the new brush painting tool 110 can be separated from or mounted on the robot 130 by the switching functions of the magnets 1123a and 1123b respectively applied to the tool changer 112.

[0124] In this regard, as an expensive system requiring pneumatic lines and ultra-precision machining processes, the pneumatic / mechanical (e.g., ball blocking) solution applied to robotic tool replacement in the prior art has the problem of deteriorated processing efficiency due to complex wires, ball wear and durability issues.

[0125] In contrast, the tool changer 160 according to an exemplary embodiment of the present invention applies switching magnetic technology through the tool changer 112 to achieve completely wireless coupling without complicated pneumatic lines and expensive systems, and increases processing efficiency based on the removal of non-operating components.

[0126] at the same time, Figure 7 A robot path generation method for sealing work according to an exemplary embodiment of the present invention is shown.

[0127] refer to Figure 7 According to an exemplary embodiment of the present invention, the robot path generator 171 generates a 3D model of a robot path required for setting the painting work of a vehicle body using a visual program by preliminarily setting the work for the painting work (S1). The visual program can define the robot path b using 3D design data or a 3D image of the vehicle body.

[0128] The robot path generator 171 receives 3D data (S2) acquired by scanning the working area of ​​the vehicle body using the 3D sensor 120 during an actual painting operation using the robot 130, and performs a preprocessing operation to extract the working area area and remove unnecessary data (e.g., background) from the 3D data (S3).

[0129] The robot path generator 171 matches the 3D model corresponding to the preprocessed 3D data in 3D to calculate a correction value according to generation of a matching error (S4).

[0130] The robot path generator 171 displays the predefined robot path in the work area of ​​the 3D data, and corrects the coordinates of the robot path according to the position of the work area of ​​the vehicle body (S5).

[0131] The robot path generator 171 controls the painting work of the robot 130 by transmitting the corrected final robot path to the robot controller 172 ( S6 ).

[0132] In this embodiment, the robot path generator 171 provides a graphical user interface (GUI) that simplifies the modification of the robot path by the user (engineer) by using offline programming (OLP).

[0133] Figure 8 A teaching condition DB construction method using an OLP-based GUI according to an exemplary embodiment of the present invention is shown.

[0134] refer to Figure 8 , the robot path generator 171 uses the GUI 173 to export the teaching points in the 3D data and provides accurate teaching and robot path modification functions for each work area expected by the user.

[0135] The robot path generator 171 generates / modifies the robot path based on the robot path of each seam working position, such as dynamic position, speed, brush rotation angle (axis-based), brush angle relative to the moving direction, brush depth, etc., by using the GUI 173, and transmits the generated / modified robot path to the robot controller 172.

[0136] In particular, the normal coordinate value of a specific point or expected position on the working seat surface of the main watertight part of the vehicle body is formed through GUI 173, and at least one of the teaching point angle (for example, based on 1 degree), the brush depth (for example, based on 1 mm) and the brush rotation angle (for example, based on 1 degree) is modified based on the normal coordinate to support precise control that simulates the painting skills of skilled workers.

[0137] Therefore, the robot path generator 171 of the embodiment of the present invention has the following effects: it is possible to solve complex problems relying on the existing manual operation of the teaching pendant, and supports robot path modification and precise control using OLP and GUI.

[0138] The robot controller 172 generates a control signal based on the robot path received from the robot path generator 171 to control the painting work of the robot 130 using the painting work tool 110 .

[0139] In addition, the robot controller 172 may control at least one operation of a residual sealant removal mode, a brush state check mode, and a tool replacement mode of the robot 130 to maintain the brush state after the painting work is completed.

[0140] The robot controller 172 may be implemented by one or more processors that are operated by a set program, and the set program may be programmed to perform each step of the sealing work automation method using the robot according to an exemplary embodiment of the present invention.

[0141] The following will refer to Fig. 9 A method for automating sealing work using a robot is described in more detail.

[0142] Meanwhile, the robot path generator 171 and the robot controller 172 may be configured as separate devices, but they may also be integrated into a control system 170, such as Figure 1 As shown, the control system 170 as a computing system may include hardware, software, and input / output interfaces for automating painting operations using a robot.

[0143] Therefore, hereinafter, when describing the sealing work automation method according to an exemplary embodiment of the present invention, the subject matter thereof will be referred to as a control system 170 .

[0144] Fig. 9 FIG. 4 is a flow chart schematically illustrating a sealing work automation method using a robot according to an exemplary embodiment of the present invention.

[0145] refer to Fig. 9 , a sealing work automation method using a robot according to an exemplary embodiment of the present invention will be described by assuming a state in which a worker applies a sealant to a seam of a vehicle body.

[0146] The control system 170 moves the painting working tool 110 and the 3D sensor 120 mounted on the robot 130 to a working position under the vehicle body ( S10 ).

[0147] The control system 170 photographs the working area of ​​the joint through the 3D sensor 120 installed on the robot 130 to obtain 3D data ( S20 ).

[0148] The control system 170 generates a robot path by matching the 3D data with a 3D model of the painting operation for the joint (S30), and controls the painting operation to spread the sealant 20a applied to the joint by moving the painting operation tool 110 along the robot path (S40). Figure 7 and 8 To describe the robot path generation method.

[0149] When the brushing operation is completed, the control system 170 moves the brushing operation tool 110 to the residual sealant remover 140 to remove the residual sealant 20b stained on the brush 111 and restore the brush shape (S50). Figure 3 to describe the residual sealant removal method.

[0150] The control system 170 captures a front image and a side image of the brush 111 from which the residual sealant 20b has been removed, to check whether the brush state is normal (OK / NG) based on image sensing (S60). Figure 4 and 5 To describe the method for determining whether the brush state is normal.

[0151] In this embodiment, when both the front image and the side image are normal (“Yes” in S70 ), the control system 170 determines that the brush state is normal (OK) and returns the robot 130 to the set home position ( S90 ).

[0152] On the contrary, the control system 170 determines that the brush state is defective (NG), and when at least one of the front image and the side image is defective (NG), NG is displayed with a warning light (No in S70).

[0153] When it is determined that the brush state is defective (NG), the control system 170 moves the robot 130 to the tool replacer 160, separates the defective brush painting tool 110 through a magnetic scheme, and then automatically replaces the defective brush painting tool 110 with a new brush painting tool 110, and installs the new brush painting tool 110 (S80). In addition, the control system 170 can return the robot 130 to the set home position (S90).

[0154] As described above, according to an exemplary embodiment of the present invention, there are the following effects: by installing a brushing operation tool optimized for the brushing operation of the sealant on a robot and using a 3D sensor to reduce the manual operation cost and to uniformize the sealant finishing quality, a precise brushing operation is controlled by a corrected robot path.

[0155] Furthermore, there is an effect that the removal of residual sealant stained on the brush, the inspection of the brush state (shape), and the replacement and installation process of old painting tools are all automated, thereby maintaining the brush shape in a state optimized for painting work.

[0156] In addition, there is the effect of using a tool changer that uses switch magnetic technology to wirelessly attach and detach brush work tools, thereby reducing replacement time and improving processing operation efficiency.

[0157] The exemplary embodiments of the present invention can be implemented not only by the above-mentioned devices and / or methods, but also by a program for implementing functions corresponding to the construction of the exemplary embodiments of the present invention, a recording medium recording the program, etc., and those skilled in the art can easily realize the implementation from the description of the above-mentioned exemplary embodiments.

[0158] While exemplary embodiments of the invention have been described in conjunction with what are presently considered to be practical exemplary embodiments, it should be understood that the scope of the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A sealing operation automation system, the system comprising: a robot configured to perform a brushing operation of spreading a sealant applied to a joint by moving a brushing operation tool to a working position at a lower portion of a vehicle body; a three-dimensional (3D) sensor mounted on the robot and configured to photograph a working area of ​​the seam to obtain 3D data; a residual sealant remover configured to remove residual sealant by applying physical force to a brush of a painting work tool that is contaminated after the painting work; a robot path generator configured to generate a robot path for a painting operation by matching the 3D data received from the 3D sensor with design data for the painting operation of the joint; as well as The robot controller is configured to control the overall operation of the robot and control the painting operation of the robot based on the robot path.

2. The system according to claim 1, wherein: The brush painting tool comprises: The brush comprises bristles with a flat front portion and a brush handle extending from the bristles in a longitudinal direction; a master changer attached to the robot and comprising a first magnet at a lower portion; and The sub-changer is configured to be mounted on or separated from the main changer through a wireless switching scheme using a second magnet configured at an upper portion when the brush is coupled through a holder.

3. The system according to claim 1, wherein: The 3D sensor is configured as: Scanning the work area with a 3D scanning camera capable of identifying depth to generate 3D data; and The generated 3D data is transmitted to the robot path generator to identify the shape of the working area and the joints where the sealant is to be applied.

4. The system according to claim 1, wherein: The robot is configured to: Controlling a scanning angle of the 3D sensor by rotating the end effector according to a working area; and The angle of the brush in the brushing direction of the joint is controlled by rotating the end effector during the brushing operation.

5. The system according to claim 1, wherein: The residual sealant remover comprises: A first sealant removal module, comprising a rod horizontally fixed to an inner wall of a housing having an upper opening, the first sealant removal module being configured to move horizontally to preliminarily remove residual sealant of the brush by physical contact; and The second sealant removing module is configured to lift the brush painting working tool while physically pressing the front and rear surfaces of the brush using urethane blocks facing each other in a horizontal direction, to secondarily remove the sealant and restore the shape of the brush.

6. The system according to claim 5, wherein: The second sealant removal module comprises: The polyurethane blocks face each other in a downwardly inclined tapered shape; movable bodies respectively coupled to the polyurethane blocks and configured to move in the left-right direction; and The actuator is configured to drive the polyurethane blocks in opposite directions through screws connected to the respective movable bodies.

7. The system according to claim 1, wherein: The robot path generator is configured as: Generate a 3D model, pre-set the work for painting, and use the vision program to set the robot path required for painting the car body; By pre-processing the 3D data received during the actual painting operation, the correction value is calculated based on the matching error generated; Matching the 3D model; Displaying a predefined robot path in a work area of ​​the 3D data; and The coordinates of the robot path are corrected according to the working position of the lower part of the vehicle body.

8. The system according to claim 1, wherein: The robot path generator is configured as: Provides a graphical user interface (GUI) to simplify user modification of robot paths by using offline programming; exporting teaching points in the 3D data using the GUI; and Provides precise teaching and robot path modification capabilities for each user-identified work area.

9. The system according to claim 8, wherein: The robot path generator is configured as: Forming the normal coordinate value of a specific point or expected position of the working seat surface of the main watertight part of the lower part of the vehicle body through the GUI; and The teach point angle, brush depth, or brush rotation angle is modified based on the normal coordinate to support precise control that mimics the painting skills of a skilled worker.

10. The system according to claim 1, wherein: The robot controller is configured to: generating a control signal based on the robot path received from the robot path generator to control the painting operation of the robot; and A residual sealant removal mode, a brush state inspection mode, or a tool replacement mode of the robot is controlled to maintain the brush state after the brushing work is completed.

11. A sealing operation automation system, the system comprising: a robot configured to perform a brushing operation of spreading a sealant applied to a joint by moving a brushing operation tool to a working position at a lower portion of a vehicle body; a three-dimensional (3D) sensor mounted on the robot and configured to photograph a working area of ​​the seam to obtain 3D data; a residual sealant remover configured to remove residual sealant by applying physical force to a brush of a painting work tool that is contaminated after the painting work; a robot path generator configured to generate a robot path for a painting operation by matching the 3D data received from the 3D sensor with design data for the painting operation of the joint; A robot controller configured to control the overall operation of the robot and control the painting operation of the robot based on the robot path; a brush inspector configured to capture a front image and a side image of the brush from which residual sealant has been removed to determine whether the brush state is normal or defective based on image sensing; and A tool replacer is configured to recover a painting work tool including a brush judged to be defective from the robot and provide a new painting work tool to replace the recovered painting work tool.

12. The system according to claim 11, wherein: The brush inspector comprises: A box, the top of which is open to define a box-shaped space; a first camera disposed on a first vertical side of the box and configured to capture a front image of the brush located at the center; a first backlight disposed on a second vertical side of the box and configured to emit light from a back side of the brush; a second camera configured to capture a side image of a first side of the brush; and A second backlight is configured to emit light from a second side of the brush.

13. The system according to claim 12, wherein: The first camera and the second camera are each configured as: In each front image or side image, the number of pixels and the brush area of ​​the brush are measured using the brightness difference of the first backlight or the second backlight; and Whether the brush state is normal or defective is determined according to whether the number of pixels and the brush area satisfy a set reference value for each of a plurality of divided sensing areas in each front image or side image.

14. The system according to claim 13, wherein: The first camera and the second camera are configured to determine that the brush state is normal under the following conditions: The brush area is located within the allowed sensing area; Only one brush area is detected in any one sensing region; and The number of pixels of the brush area of ​​each sensing region meets the set reference value.

15. The system according to claim 11, wherein: The tool changer comprises: A plurality of tool supports, horizontally arranged in the T-shaped support and defining a base structure of the brush working tool; and The proximity sensor is configured to detect whether the painting tool is located on each tool support and transmit the information to the robot controller whether the painting tool is located on each tool support.

16. A method for automating sealing operations using a robot, the method comprising the following steps: The painting tool and the three-dimensional (3D) sensor mounted on the robot are moved to a working position on the lower part of the vehicle body, and the working area of ​​the joint is photographed by the 3D sensor to obtain 3D data; generating a robot path by matching the 3D data with a 3D model of the painting operation of the joint; Controlling the brushing operation to spread the sealant applied to the joint by moving the brushing operation tool along the robot path; moving the brush painting tool to a residual sealant remover to remove residual sealant stained on the brush of the brush painting tool and restore the brush shape after the brush painting work is completed; The brush inspector takes a front image and a side image of the brush to determine whether the brush is normal or defective based on image sensing; as well as In the case where the state of the brush is judged to be defective, the painting work tool is moved to a tool replacer, the painting work tool is separated by a magnetic scheme, the painting work tool is replaced with a new painting work tool, and the new painting work tool is installed.

17. The method according to claim 16, wherein: The steps to generate a robot path include: generating a 3D model using a visual program, the 3D model setting a robot path required for painting the lower part of the vehicle body; Performing pre-processing operations to extract the area of ​​the working area from the 3D data and remove unnecessary data in the painting operation; According to the generation of the matching error, matching in 3D a 3D model corresponding to the preprocessed 3D data to calculate a correction value; and A predefined robot path is displayed in the work area of ​​the 3D data, and the coordinates of the robot path are corrected according to the work position of the lower part of the vehicle body.

18. The method according to claim 16, wherein: The steps to remove the residual sealant and restore the brush to shape include: Preliminarily removing residual sealant stained on the brush by physically contacting the brush with a horizontal fixing rod of the first sealant removal module; and The residual sealant is secondarily removed and the brush shape is restored by raising the brush working tool while physically pressing the front and back sides of the brush using urethane blocks of a second sealant removal module, which face each other in a horizontal direction.

19. The method according to claim 16, wherein: The steps of taking a front image and a side image of the brush to determine whether the brush is in a normal state or defective include: for each of the front image and the side image, measuring the number of pixels and the brush area of ​​the brush, and judging whether the brush state is normal or defective according to whether the number of pixels and the brush area meet the set reference value of each of the plurality of divided sensing areas in each of the front image or the side image; and The brush state is judged to be normal under the following conditions: The brush area is located within the allowed sensing area; Only one brush area is detected in any one sensing region; and The number of pixels of the brush area of ​​each sensing region meets the set reference value.

20. The method according to claim 16, wherein: The steps of replacing the brush painting tool with a new brush painting tool and installing the new brush painting tool include: moving the robot to an empty first tool holder of a tool changer, detaching the painting tool from the robot, and mounting the detached painting tool on the empty first tool holder; and The robot is moved to a second tool support, a new painting tool is mounted on the robot, and the robot is returned to its original position.

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