Automatic coating method and system

Abstract

The invention discloses an automatic coating method and system, relates to the technical field of automatic manufacturing and detection, and is used for solving the problems that the production cost is increased and the coating quality is unstable due to the fact that deviation and defects during coating cannot be treated in time and manual intervention inspection is depended during automatic coating. The method comprises the following steps: acquiring target information of a to-be-coated area; the to-be-coated area is a plane area containing an inflection point, and the target information at least comprises a coordinate of a coating end point of the to-be-coated area and a coordinate of the inflection point; based on the target information, determining a movement track of the coating device on the to-be-coated area; controlling an image detection device to detect a real-time detection image on the movement track in real time; and based on the motion trail and the real-time detection image, the coating device is controlled to conduct coating, and when the real-time detection image shows that the coating quality is unqualified, the coating device is controlled to conduct supplementary coating at the position where coating is unqualified. Deviation and defects during coating can be treated in time, the cost is reduced, and the coating quality is improved.

Description

Technical Field

[0001] The present invention relates to the field of automated manufacturing and detection technology, and in particular to an automatic coating method and system. Background Art

[0002] Coating is a technical process of applying a coating on the surface of a product. It is often used for product protection. The surface coating quality of some parts directly affects the overall quality and appearance of the product.

[0003] However, traditional automated coating devices can usually only complete a single coating action and lack a real-time coating quality detection mechanism. When there is a slight deviation in the coating process of the component or there is a coating leak or coating interruption during the coating process, these devices are often unable to detect and correct them in time, and manual intervention and inspection are still required, thus failing to achieve true fully automated production. This not only increases labor costs, but may also lead to unstable coating quality and affect the overall quality of the product. Summary of the invention

[0004] The purpose of the present invention is to provide an automatic coating method and system to solve the problem in the prior art that deviations and defects during coating cannot be handled in a timely manner during automatic coating, and manual intervention and inspection are relied upon, resulting in increased production costs and unstable coating quality.

[0005] In order to achieve the above object, the present invention provides the following technical solutions:

[0006] In a first aspect, the present invention provides an automatic coating method, the method comprising:

[0007] Acquire target information of the area to be coated; the area to be coated is a planar area including an inflection point, and the target information at least includes the coordinates of the coating end point of the area to be coated and the coordinates of the inflection point;

[0008] Based on the target information, determining a motion trajectory of the coating device on the area to be coated;

[0009] Control the image detection device to detect the real-time detection image on the motion trajectory in real time;

[0010] Based on the motion trajectory and the real-time detection image, the coating device is controlled to perform coating. When the real-time detection image shows that the coating quality is unqualified, the coating device is controlled to perform re-coating at the unqualified coating position.

[0011] Optionally, in the above-mentioned automatic coating method, obtaining target information of the area to be coated specifically includes:

[0012] The image of the area to be coated is processed by using a threshold segmentation algorithm, an edge detection algorithm and a neural network model to obtain target information.

[0013] Optionally, in the above-mentioned automatic coating method, based on the target information, determining the motion trajectory of the coating device on the area to be coated specifically includes:

[0014] One of the inflection points is selected as the coating starting point, and a corresponding motion trajectory is established between the coating starting point and the coating end point.

[0015] Optionally, in the above-mentioned automatic coating method, the motion trajectory includes a first motion trajectory and a second motion trajectory, the first motion trajectory includes a first inflection point, a second inflection point and a first coating end point, and the second motion trajectory includes a first inflection point and a second coating end point;

[0016] Select one of the inflection points as the coating starting point, and establish a corresponding motion trajectory between the coating starting point and the coating end point, specifically including:

[0017] The first inflection point is selected as the coating starting point, and a first motion trajectory is established between the first inflection point and the first coating end point; the second inflection point is located on the first motion trajectory;

[0018] A second motion trajectory is established between the coating starting point and the second coating end point.

[0019] Optionally, in the above-mentioned automatic coating method, controlling the coating device to perform coating based on the motion trajectory and the real-time detection image includes:

[0020] Based on the first motion trajectory, controlling the coating device to coat along the first motion trajectory until a first coating end point;

[0021] The coating device is controlled to move from the first coating end point to the coating starting point along the direction of the shortest distance, and based on the second motion trajectory, the coating device is controlled to coat along the second motion trajectory until the end point of the second motion trajectory.

[0022] Optionally, in the above-mentioned automatic coating method, controlling the coating device to perform coating based on the motion trajectory and the real-time detection image includes:

[0023] Based on the first motion trajectory, controlling the coating device to coat along the first motion trajectory until an end point of the first motion trajectory;

[0024] The coating device is controlled to move along the opposite direction of the first motion trajectory to the coating starting point, and based on the second motion trajectory, the coating device is controlled to perform coating along the second motion trajectory until the end point of the second motion trajectory.

[0025] Optionally, in the above-mentioned automatic coating method, when the real-time detection image shows that the coating quality is unqualified, controlling the coating device to perform re-coating at the unqualified coating position specifically includes:

[0026] Get the repainting times threshold; the repainting times threshold is the maximum allowed repainting times;

[0027] A neural network model is used to detect whether the real-time detection image is an unqualified image. If the real-time detection image is a qualified image, coating continues along the motion trajectory; if the real-time detection image is an unqualified image, the coating device is controlled to return to the position before the unqualified area to be coated for re-coating;

[0028] The number of touch-ups is accumulated and compared with the touch-up threshold. If the number of touch-ups is less than or equal to the touch-up threshold, coating continues along the motion trajectory until coating is completed; if the number of touch-ups is greater than the touch-up threshold, coating is terminated.

[0029] Compared with the prior art, the present invention provides an automatic coating method, which obtains the target information of the area to be coated; wherein the area to be coated is a planar area containing an inflection point, and the target information at least includes the coordinates of the coating end point of the area to be coated and the coordinates of the inflection point; based on the target information, the motion trajectory of the coating device on the area to be coated is determined; the image detection device is controlled to detect the real-time detection image on the motion trajectory in real time; based on the motion trajectory and the real-time detection image, the coating device is controlled to perform coating, and when the real-time detection image shows that the coating quality is unqualified, the coating device is controlled to perform re-coating at the unqualified coating position. The present invention achieves real-time monitoring of coating quality and timely re-coating when unqualified through real-time image detection by accurately locating and planning the motion trajectory, thereby improving the coating quality and reducing cost waste.

[0030] In a second aspect, the present invention provides an automatic coating system, the system comprising:

[0031] An image acquisition device for acquiring an image of the area to be coated;

[0032] A coating device, used for coating the area to be coated;

[0033] An image detection device, which is fixedly arranged on the coating device and is used to obtain a real-time detection image on the motion track;

[0034] A controller, wherein the controller is respectively connected to the image acquisition device, the coating device and the image detection device for communication, and is used for processing the image to obtain target information of the area to be coated, and based on the target information, determining the motion trajectory of the coating device on the area to be coated; wherein the area to be coated is a planar area including an inflection point, and the target information at least includes the coating end point coordinates and the inflection point coordinates of the area to be coated; and based on the real-time monitoring image obtained by the image detection device, the coating device is controlled to coat along the motion trajectory, and when the real-time detection image shows that the coating quality is unqualified, the coating device is controlled to perform re-coating at the unqualified coating position.

[0035] Optionally, in the above-mentioned automatic coating system, the area to be coated is a rectangular area, and the image acquisition device includes five high-position cameras, which are respectively arranged above the four corners and one side of the rectangular area, for capturing images of the four corners and one side of the rectangular area.

[0036] Optionally, in the above-mentioned automatic coating system, the automatic coating system further comprises:

[0037] The alarm device is connected to the controller for sending out an alarm message when the number of re-coating times exceeds a threshold.

[0038] The technical effects achieved by the system-type solutions provided in the second aspect are the same as those achieved by the method-type solutions provided in the first aspect, and will not be repeated here. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0040] Figure 1 A schematic flow chart of an automatic coating method provided by an embodiment of the present invention;

[0041] Figure 2 A schematic diagram of a specific process of an automatic coating method provided by an embodiment of the present invention;

[0042] Figure 3 A schematic diagram of a re-coating process of an automatic coating method provided by an embodiment of the present invention;

[0043] Figure 4 A schematic diagram of the overall structure of an automatic coating system provided by an embodiment of the present invention;

[0044] Figure 5 A side view of an automatic coating system provided by an embodiment of the present invention;

[0045] Figure 6 A front view of an automatic coating system provided in an embodiment of the present invention.

[0046] Reference numerals:

[0047] 1 is an image acquisition device, 2 is a coating device, 3 is an image detection device, and 4 is a controller. DETAILED DESCRIPTION

[0048] In order to clearly describe the technical solutions of the embodiments of the present invention, in the embodiments of the present invention, words such as "first" and "second" are used to distinguish the same items or similar items with basically the same functions and effects. For example, the first threshold and the second threshold are only used to distinguish different thresholds, and their order is not limited. Those skilled in the art can understand that words such as "first" and "second" do not limit the quantity and execution order, and words such as "first" and "second" do not necessarily limit them to be different.

[0049] It should be noted that, in the present invention, words such as "exemplary" or "for example" are used to indicate examples, illustrations or descriptions. Any embodiment or design described as "exemplary" or "for example" in the present invention should not be interpreted as being more preferred or more advantageous than other embodiments or designs. Specifically, the use of words such as "exemplary" or "for example" is intended to present related concepts in a specific way.

[0050] In the present invention, "at least one" means one or more, and "plurality" means two or more. "And / or" describes the association relationship of associated objects, indicating that three relationships may exist. For example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone, where A and B can be singular or plural. The character " / " generally indicates that the associated objects before and after are in an "or" relationship. "At least one of the following" or similar expressions refers to any combination of these items, including any combination of single or plural items. For example, at least one of a, b or c can mean: a, b, c, the combination of a and b, the combination of a and c, the combination of b and c, or the combination of a, b and c, where a, b, c can be single or multiple.

[0051] Next, the solution provided by the embodiments of this specification is described in conjunction with the accompanying drawings:

[0052] like Figure 1 As shown, the process may include the following steps:

[0053] Step 110: Acquire target information of the area to be coated; the area to be coated is a planar area including an inflection point, and the target information at least includes the coordinates of the coating end point of the area to be coated and the coordinates of the inflection point.

[0054] In this technical solution, the workpiece to be coated needs to be transported to the bottom of the coating device first. This process involves the preliminary positioning operation of the transport device. The transport device gradually moves the workpiece to be coated closer to the area where the coating device is located according to the preset program instructions, and ensures that the area to be coated is accurately within the working range of the coating device. After the workpiece to be coated reaches the appropriate position under the coating device, it starts to obtain the target information of the area to be coated. By determining this target information, basic data is provided for the subsequent determination of the motion trajectory of the coating device.

[0055] Step 120: determining a motion trajectory of a coating device on the area to be coated based on the target information;

[0056] In step 110, the coating end point coordinates and inflection point coordinates in the target information provide a basic framework for planning the motion trajectory. When the coating end point coordinates are determined, the final destination of the coating is clear, and the motion path of the coating device must extend to this point to complete the coating task of the entire area. The inflection point coordinates are key nodes in the trajectory. When passing through these inflection points, the coating device needs to change the direction of movement to adapt to the changes in the shape of the area to be coated.

[0057] Step 130: Control the image detection device to detect the real-time detection image on the motion trajectory in real time.

[0058] The purpose of this step is to capture the coating image on the motion trajectory at every moment of the coating device's movement. These images are real-time detection images. When the coating device starts to move along the motion trajectory at the coating starting point of the area to be coated, the image detection device starts synchronously to accurately capture the coating image on the motion trajectory. With this arrangement, problems such as coating leakage, uneven coating, or unclear coating can be captured in real time during the coating process. If the coating device has an abnormal discharge or fails to achieve good coating due to posture adjustment, the real-time detection function of the image detection device can detect and deal with quality problems as soon as they occur.

[0059] Step 140: Based on the motion trajectory and the real-time detection image, control the coating device to perform coating; when the real-time detection image shows that the coating quality is unqualified, control the coating device to perform re-coating at the unqualified coating position.

[0060] During the automatic coating process, the coating device performs coating operations according to a predetermined motion trajectory, and at the same time, the image detection device synchronously acquires real-time detection images along the motion trajectory. These images are transmitted and analyzed in real time to determine whether the coating quality is qualified. When it is determined that the coating quality is unqualified, the coating device will be immediately controlled to stop the current coating process, and accurately locate the unqualified coating position based on the recorded motion trajectory and image detection information. After that, the coating device returns to the unqualified position, adjusts the coating parameters, and performs the coating operation again to make up for the previous coating defects, thereby improving the coating quality and coating efficiency.

[0061] Figure 1 The method in the method, by obtaining the target information of the area to be coated; the area to be coated is a planar area containing an inflection point, and the target information at least includes the coordinates of the coating end point of the area to be coated and the coordinates of the inflection point; based on the target information, the motion trajectory of the coating device on the area to be coated is determined; the image detection device is controlled to detect the real-time detection image on the motion trajectory in real time; based on the motion trajectory and the real-time detection image, the coating device is controlled to perform coating, and when the real-time detection image shows that the coating quality is unqualified, the coating device is controlled to perform re-coating at the unqualified coating position. By accurately positioning and planning the motion trajectory on the part to be coated, and by using real-time image detection to realize real-time monitoring of the coating quality and timely re-coating when it is unqualified, the coating quality qualification rate is improved and cost waste is reduced.

[0062] based on Figure 1 The method in this specification also provides some specific implementation methods of the method, which are described below.

[0063] In the technical solution provided by the present invention, a specific implementation method of applying the technical solution provided by the present invention to the back panel of a television set is proposed. It can be understood that the technical solution provided by the present invention is not limited to the back panel of a television set when applied, as long as the area to be coated is a plane area with an inflection point. The technical solution provided by the present invention is further described below using the back panel of a television set as the part to be coated.

[0064] like Figure 2As shown, first, the TV back panel is transported to a specific working area under the coating device, and this transportation process is precisely performed by a specially designed conveyor line. According to the preset program and positioning mechanism, the conveyor line places the TV back panel steadily and accurately in a position where the coating device can work effectively. After that, the arrival signal of the part to be coated is detected, and the image acquisition device is used to acquire the position image of the area to be coated and send it to the controller. Then, the controller processes the acquired image to obtain the target information of the area to be coated on the TV back panel. In this process, the high-position camera calibrates the internal and external parameters for the shooting height and field of view corresponding to the back panels of different series of TVs, realizes the conversion of the camera coordinate system to the coordinate system of the end of the robot arm, and then accurately extracts the target information of the area to be coated on the TV back panel, which at least covers the coordinates of the coating end point and the inflection point, and may also include the back panel boundary information, surface feature information, etc. Based on the acquired target information, the motion trajectory of the coating device on the area to be coated on the TV back panel is determined. Select one of the inflection points as the coating starting point, and construct a reasonable motion trajectory between the coating starting point and the coating end point. For example, there may be different situations such as the first motion trajectory including the first inflection point, the second inflection point and the first coating end point, and the second motion trajectory including the first inflection point and the second coating end point. Plan an efficient coating path that fits the shape of the TV back panel to ensure the comprehensiveness and uniformity of the coating process.

[0065] like Figure 2 As shown, during the coating process, the coating device coats along the motion trajectory, while the image detection device detects the coating effect, and the image detection device detects the image on the motion trajectory in real time. The image detection device continuously captures the coated fragments during the entire coating process, and uploads the real-time detection image to the controller. The controller uses a neural network model to detect whether the coating image is an unqualified image. When quality problems such as missing coating, uneven thickness, and unclear coating boundaries are detected, a stop signal is sent to the coating device, and the coating point before the image is unqualified is sent. After receiving the signal, the coating device returns to the unqualified coating position for re-coating. If the image is still detected to be unqualified after re-coating, it is judged according to the re-coating number threshold. When the re-coating number is less than the threshold, the re-coating process is repeated; when the re-coating number is greater than the threshold, an alarm is triggered and the coating is ended. Through such an automatic coating and inspection mechanism, the quality and efficiency of TV back panel coating are effectively improved, the uncertainty and cost caused by manual intervention are reduced, the automation, intelligence and precision of TV back panel coating operations are realized, and the overall performance and reliability of the coating link in the TV back panel production process are greatly improved, meeting the needs of large-scale, high-quality production of TV back panels.

[0066] like Figure 3As shown, the embodiment of the present invention provides a specific process for repainting a rectangular area. First, visual inspection is started at the starting point of coating a single edge, and then coating is performed and visual inspection is carried out at the same time. Then, it is judged whether the coating is qualified: if the coating is unqualified, it is judged whether it exceeds the repainting number threshold; if it exceeds the repainting number threshold, an alarm is triggered and the coating ends; if it does not exceed the repainting number threshold, it returns to re-coat and conducts visual inspection again; if the coating is qualified, it is judged whether the single side is coated; if the single side is coated, it is judged whether the two wide sides and one long side are coated. If they are coated, the whole coating process ends; if the single side is not coated or the two wide sides and one long side are not coated, it returns to continue coating and conducts visual inspection.

[0067] Optionally, in the automatic coating detection method provided by the present invention, obtaining target information of the area to be coated specifically includes: using a threshold segmentation algorithm, an edge detection algorithm and a neural network model to process the acquired image of the area to be coated to obtain the target information.

[0068] For the area to be coated, such as the back plate of the TV, the image acquisition device first obtains its image. Then the controller uses the threshold segmentation algorithm to set the threshold according to the difference in pixel values ​​of different areas in the back plate image, preliminarily distinguishes the area to be coated from the background area, and quickly locates the approximate coating range outline, which helps to narrow the scope of subsequent analysis and improve processing efficiency; then the edge detection algorithm is used to further process the image, accurately detect the positions where the pixel values ​​in the image change dramatically, which often correspond to the edges of the area to be coated on the back plate of the TV and key positions such as inflection points, so as to accurately outline the detailed shape information of the coating area, and provide a reliable basis for determining the coating end point and inflection point coordinates; the neural network model is deeply optimized on the basis of the existing algorithm, and the neural network is trained through a large amount of pre-annotated TV back plate image data, so that it can learn the unique patterns of TV back plate coating areas of different models and different shape features. When the actual TV back plate image to be coated is input, the neural network can accurately identify the coating end point coordinates and the coordinates of each inflection point, and can also make intelligent judgments and compensations for some complex features, such as edge blurring caused by minor defects or special textures on the back plate surface, further improving the accuracy of target information acquisition.

[0069] This method of acquiring target information through a combination of multiple algorithms and models improves the accuracy of target information acquisition. Compared with the traditional single algorithm or manual measurement and positioning method, it can more accurately determine the key coating positions on the TV back panel, thereby providing extremely accurate data support for the motion trajectory planning of the subsequent coating device, effectively avoiding coating deviations, missed coating or over-coating caused by target information errors, and improving coating quality. At the same time, the automated information acquisition process reduces the time and labor costs of manual operations, improves the efficiency of the entire coating operation, and is conducive to the efficient operation of large-scale automated production of TV back panel coating operations.

[0070] Optionally, based on the target information, determining the motion trajectory of the coating device on the area to be coated specifically includes: selecting one of the inflection points as the coating starting point, and establishing a corresponding motion trajectory between the coating starting point and the coating end point.

[0071] After determining the target information such as the coating end point coordinates and the coordinates of each inflection point of the TV back panel area to be coated, a corner inflection point is selected as the coating start point, so that the coating device can more conveniently adjust the state and start the coating operation when it is started, reducing the preparation time and risk of errors in the initial stage. A corresponding motion trajectory is established between the coating start point and the coating end point.

[0072] Further, the motion trajectory includes a first motion trajectory and a second motion trajectory, the first motion trajectory includes a first inflection point, a second inflection point and a first coating end point, and the second motion trajectory includes a first inflection point and a second coating end point;

[0073] The step of selecting one of the inflection points as the coating starting point and establishing a corresponding motion trajectory between the coating starting point and the coating end point specifically includes:

[0074] The first inflection point is selected as the coating starting point, and the first motion trajectory is established between the first inflection point and the first coating end point; the second inflection point is located on the first motion trajectory;

[0075] The second motion trajectory is established between the coating starting point and the second coating end point.

[0076] Such setting, on the one hand, improves the accuracy of coating. Through the motion trajectory specially designed for the characteristics of different areas, the paint can be accurately applied to the predetermined position, so that the coating effect of the TV back panel can reach the ideal state in every detail, thereby improving the product appearance quality and protective performance; on the other hand, the accuracy of coating is improved. Through the motion trajectory specially designed for the characteristics of different areas, the paint can be accurately applied to the predetermined position, so that the coating effect of the TV back panel can reach the ideal state in every detail, thereby improving the product appearance quality and protective performance.

[0077] Further, after the motion trajectory is determined, the coating device is controlled to perform coating based on the motion trajectory and the detection image, specifically including:

[0078] Based on the first motion trajectory, controlling the coating device to coat along the first motion trajectory until the first coating end point;

[0079] The coating device is controlled to move from the first coating end point to the coating starting point along the direction of the shortest distance, and based on the second motion trajectory, the coating device is controlled to coat along the second motion trajectory until the end point of the second motion trajectory.

[0080] When controlling the coating device to coat along the first motion trajectory until the first coating end point, the controller will reasonably adjust the motion posture and coating parameters of the coating device according to information such as the position and angle of the inflection point to ensure high-quality coating on the first motion trajectory and avoid problems such as missing coating, uneven thickness or unclear coating.

[0081] After reaching the first coating end point, the coating device is controlled to move to the coating starting point along the shortest distance direction. This process is intended to reduce the idle travel time of the coating device and improve the overall coating efficiency. Since the coating device does not perform coating operations during the movement, by selecting the shortest distance path, it can quickly return to the starting point and prepare for the coating of the next second motion trajectory.

[0082] Next, coating is performed based on the second motion trajectory until the end point, and other parts of the TV back panel that are different from the area covered by the first motion trajectory can be coated, thereby achieving comprehensive coating of the entire TV back panel. Through precise trajectory control and trajectory planning for different areas, it can ensure that all parts of the TV back panel are coated evenly, completely and with high quality, improving the overall quality and appearance of the product, which is especially important for products such as TVs that have high requirements for appearance. Secondly, in terms of efficiency, by rationally planning the coating sequence and shortening the idle travel distance, the time waste in the coating process is reduced, the production efficiency is improved, and more TV back panels can be coated per unit time, meeting the needs of large-scale production and reducing production costs.

[0083] In some embodiments, after reaching the first coating end point, the coating device is controlled to move in the opposite direction of the first motion trajectory to the coating starting point. By moving in the opposite direction of the first motion trajectory, the coating device can use the path information and posture adjustment data accumulated during the previous movement. Since parameters such as the steering angle at the turning point and the coating height in different areas have been accurately set and adapted when coating along the first motion trajectory in the forward direction, these paths can be repeated more accurately when moving in the reverse direction, reducing errors that may be caused by replanning the path or adjusting the posture. Compared to opening up a new path or taking the shortest distance, which may involve complex environmental judgments, moving in the opposite direction of the first motion trajectory can avoid safety accidents such as equipment collisions caused by trajectory planning errors or misjudgments of the surrounding environment, and ensure the continuity and reliability of the entire coating process.

[0084] As a possible implementation, when the detection image shows that the coating quality is unqualified, controlling the coating device to perform re-coating at the unqualified coating position specifically includes:

[0085] Get a re-coating times threshold; the re-coating times threshold is the maximum allowed re-coating times;

[0086] A neural network model is used to detect whether the real-time detection image is an unqualified image. If the real-time detection image is a qualified image, coating is continued along the motion trajectory; if the real-time monitoring image is an unqualified image, the coating device is controlled to return to the position of the area to be coated before the unqualified image is reached for re-coating;

[0087] The number of touch-ups is accumulated and compared with the touch-up threshold. If the number of touch-ups is less than or equal to the touch-up threshold, coating is continued along the motion trajectory until coating is completed; if the number of touch-ups is greater than the touch-up threshold, coating is terminated.

[0088] First, obtaining the re-coating threshold clarifies the maximum permissible number of re-coatings during the quality control process. The setting of this threshold is the result of comprehensive consideration of many factors, which may include the production efficiency requirements of the TV back panel or the coating cost or the potential impact of multiple coatings on the surface quality of the TV back panel. After the re-coating threshold is determined, a neural network model is used to detect whether the real-time detection image is an unqualified image. The neural network model is trained with a large number of sample images and can accurately identify various coating defects. If the detection image is a qualified image, the coating device will coat along a predetermined motion trajectory. When an unqualified image is detected, the coating device is controlled to return to the position before the unqualified area to be coated for re-coating. This operation can accurately locate the problem area and avoid unnecessary interference with the qualified area. In the process of re-coating, the number of re-coatings is accumulated and compared with the number of re-coatings. The coating quality problem is corrected by re-coating. After the re-coating is completed, the coating device continues to coat along the preset motion trajectory until the coating task of the entire back panel is completed. However, when the re-coating number is greater than the threshold, the coating is terminated and the corresponding processing mechanism is triggered, such as triggering an alarm for manual inspection or directly determining that the TV back panel is an unqualified product for subsequent processing. This mechanism effectively balances the relationship between coating quality and production efficiency, which can not only guarantee the coating quality of the TV back panel to a certain extent and reduce the risk of quality problems entering the market, but also avoid production delays and cost out of control due to unlimited re-coating, thereby ensuring the efficiency, stability and controllability of the entire TV back panel coating production process.

[0089] Based on the same idea, the present specification also provides an automatic coating system. Figure 4-Figure 6 As shown, the system includes:

[0090] An image acquisition device 1, used to acquire an image of the area to be coated;

[0091] A coating device 2, used for coating the area to be coated;

[0092] An image detection device 3, the image detection device 3 is fixedly arranged on the coating device 2, and is used to obtain a real-time detection image on a motion track;

[0093] A controller 4, wherein the controller 4 is respectively connected to the image acquisition device 1, the coating device 2 and the image detection device 3 in communication, and the controller 4 is used to process the image to obtain target information of the area to be coated, and based on the target information, determine the movement trajectory of the coating device 2 on the area to be coated; wherein the area to be coated is a planar area including an inflection point, and the target information at least includes the coating end point coordinates and the inflection point coordinates of the area to be coated; and based on the real-time monitoring image obtained by the image detection device 3, the coating device 2 is controlled to coat along the movement trajectory, and when the real-time detection image shows that the coating quality is unqualified, the coating device 2 is controlled to perform re-coating at the unqualified coating position.

[0094] Compared with the prior art, the present invention provides an automatic coating system, such as Figure 4-Figure 6 As shown, by setting up an image acquisition device 1, an image of the area to be coated is acquired, and the acquired image is transmitted to the controller 4. The controller 4 uses algorithms and models to extract the target information of the area to be coated, including the coordinates of the coating end point and the inflection point, etc., and accurately identifies the key position information in the image to plan a reasonable motion trajectory for the coating device 2; during the coating process, the controller 4 controls the coating device 2 to coat along the predetermined trajectory according to the real-time detection image fed back by the image detection device 3, and when the quality is found to be unqualified, the coating device 2 is quickly instructed to re-coat at the unqualified position. It can also record and manage the number of re-coating times, and compare it with the preset re-coating number threshold to decide whether to continue re-coating or end the coating operation, thereby effectively ensuring the coating quality, improving production efficiency, reducing the increase in production costs caused by quality problems, and realizing the efficient operation of the entire automatic coating system in application scenarios such as TV back panel coating.

[0095] As a possible implementation, Figure 4As shown, five high-position cameras with a specific layout are used as image acquisition devices 1 for the rectangular area to be coated. The rectangular area has four corners and four sides. The five high-position cameras are respectively set at the four corners of the rectangular area and above one side, so that the rectangular area to be coated can be imaged from multiple key perspectives. The cameras at the four corners can accurately capture the corner features of the rectangle, which helps to determine the boundary of the area to be coated and the possible inflection point coordinates. The camera set above one side can supplement the image details of this side and the side opposite to it. When processing the rectangular area, the two opposite sides have similar geometric features. By collecting the image of one side with one camera, combined with the image information of the other four corner cameras, the controller 4 can use the image processing algorithm to deduce the shape and position information of the relative side, thereby completely constructing the image model of the rectangular area to be coated, reducing the number of cameras used, and reducing the system cost and data processing volume while meeting the image acquisition requirements. The images collected by the five cameras from different directions complement and verify each other, which can effectively reduce the image blind spots or errors caused by the limitation of the single camera viewing angle. Thereby improving the reliability of image acquisition and providing support for the subsequent accurate extraction of target information of the area to be coated.

[0096] It should be noted that if Figure 6 As shown, the image detection device 3 is fixedly connected to the coating device 2 and moves synchronously with the coating device 2. The image detection device 3 uses a high frame rate camera, which can adapt to the scene where the detection object moves rapidly, thereby obtaining a real-time detection image on a high frame rate motion trajectory.

[0097] Furthermore, the automatic coating system further comprises: an alarm device, which is in communication connection with the controller 4 and is used for issuing an alarm message when the number of re-coating exceeds a threshold value.

[0098] When the coating process fails to meet the quality standards, the system will control the coating equipment to perform re-coating. The re-coating threshold is an important pre-set parameter that limits the maximum number of re-coatings that can be performed on an area to be coated. When the number of re-coatings exceeds this threshold, it means that re-coating may no longer be able to effectively solve the coating quality problem, or that continuing to re-coat will result in negative effects such as excessively high costs and low production efficiency.

[0099] At this time, the alarm device connected to the controller 4 will play a role. It can send out alarm information in time, and this alarm information can be in various forms, such as sound alarm, light alarm or sending prompt information to relevant personnel. The existence of the alarm device ensures that the operator can be informed of the abnormal situation that exceeds the threshold of the number of re-coating times during the coating process at the first time. After receiving the alarm information, the operator can promptly check the coating device 2, the coating, the parts to be coated, etc., to determine whether it is equipment failure, coating quality problems or other factors that cause the coating quality to continue to fail to meet the standards. This can avoid the continued production of unqualified products and reduce production waste. It also helps to quickly troubleshoot and solve problems and ensure the normal operation and production efficiency of the automatic coating system.

[0100] Although the present invention is described herein in conjunction with various embodiments, in the process of implementing the claimed invention, those skilled in the art may understand and implement other variations of the disclosed embodiments by viewing the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other components or steps, and "one" or "an" does not exclude multiple situations. A single processor or other unit may implement several functions listed in the claims. Certain measures are recorded in different dependent claims, but this does not mean that these measures cannot be combined to produce good results.

[0101] Although the present invention has been described in conjunction with specific features and embodiments thereof, it is apparent that various modifications and combinations may be made thereto without departing from the spirit and scope of the present invention. Accordingly, this specification and the accompanying drawings are merely exemplary illustrations of the present invention as defined by the appended claims and are deemed to cover any and all modifications, variations, combinations or equivalents within the scope of the present invention. Obviously, those skilled in the art may make various modifications and variations to the present invention without departing from the spirit and scope of the present invention. Thus, the present invention is intended to include such modifications and variations if they fall within the scope of the claims of the present invention and their equivalents.

Claims

1. An automatic coating method, characterized in that: include: Acquire target information of the area to be coated; the area to be coated is a planar area including an inflection point, and the target information at least includes the coordinates of the coating end point of the area to be coated and the coordinates of the inflection point; Based on the target information, determining a motion trajectory of a coating device on the area to be coated; Controlling the image detection device to detect the real-time detection image on the motion trajectory in real time; Based on the motion trajectory and the real-time detection image, the coating device is controlled to perform coating. When the real-time detection image shows that the coating quality is unqualified, the coating device is controlled to perform re-coating at the unqualified coating position.

2. The automatic coating method according to claim 1, characterized in that: The obtaining of target information of the area to be coated specifically includes: The image of the area to be coated is acquired by processing the image using a threshold segmentation algorithm, an edge detection algorithm and a neural network model to obtain the target information.

3. The automatic coating method according to claim 1, characterized in that: Based on the target information, determining the motion trajectory of the coating device on the area to be coated specifically includes: One of the inflection points is selected as a coating starting point, and a corresponding motion trajectory is established between the coating starting point and the coating end point.

4. The automatic coating method according to claim 3, characterized in that: The motion trajectory includes a first motion trajectory and a second motion trajectory, the first motion trajectory includes a first inflection point, a second inflection point and a first coating end point, and the second motion trajectory includes a first inflection point and a second coating end point; The step of selecting one of the inflection points as the coating starting point and establishing a corresponding motion trajectory between the coating starting point and the coating end point specifically includes: The first inflection point is selected as the coating starting point, and the first motion trajectory is established between the first inflection point and the first coating end point; the second inflection point is located on the first motion trajectory; The second motion trajectory is established between the coating starting point and the second coating end point.

5. The automatic coating method according to claim 4, characterized in that: The controlling the coating device to perform coating based on the motion trajectory and the real-time detection image comprises: Based on the first motion trajectory, controlling the coating device to coat along the first motion trajectory until the first coating end point; The coating device is controlled to move from the first coating end point to the coating starting point along the direction of the shortest distance, and based on the second motion trajectory, the coating device is controlled to coat along the second motion trajectory until the end point of the second motion trajectory.

6. The automatic coating method according to claim 4, characterized in that: The controlling the coating device to perform coating based on the motion trajectory and the real-time detection image comprises: Based on the first motion trajectory, controlling the coating device to coat along the first motion trajectory until an end point of the first motion trajectory; The coating device is controlled to move along the opposite direction of the first motion trajectory to the coating starting point, and based on the second motion trajectory, the coating device is controlled to perform coating along the second motion trajectory until the end point of the second motion trajectory.

7. The automatic coating method according to any one of claims 1 to 6, characterized in that: When the real-time detection image shows that the coating quality is unqualified, controlling the coating device to perform re-coating at the unqualified coating position specifically includes: Get a re-coating times threshold; the re-coating times threshold is the maximum allowed re-coating times; A neural network model is used to detect whether the real-time detection image is an unqualified image. If the real-time detection image is a qualified image, coating is continued along the motion trajectory; if the real-time detection image is an unqualified image, the coating device is controlled to return to the position of the area to be coated before the unqualified image is reached for re-coating; The number of touch-ups is accumulated and compared with the touch-up threshold. If the number of touch-ups is less than or equal to the touch-up threshold, coating is continued along the motion trajectory until coating is completed; if the number of touch-ups is greater than the touch-up threshold, coating is terminated.

8. An automatic coating system, characterized in that: include: An image acquisition device for acquiring an image of the area to be coated; A coating device, used for coating the area to be coated; An image detection device, which is fixedly disposed on the coating device and is used to obtain a real-time detection image on a motion track; A controller, wherein the controller is respectively communicatively connected with the image acquisition device, the coating device and the image detection device, and the controller is used to process the image to obtain target information of the area to be coated, and based on the target information, determine the movement trajectory of the coating device on the area to be coated; wherein the area to be coated is a planar area containing an inflection point, and the target information at least includes the coating end point coordinates and the inflection point coordinates of the area to be coated; and based on the real-time monitoring image obtained by the image detection device, the coating device is controlled to coat along the movement trajectory, and when the real-time detection image shows that the coating quality is unqualified, the coating device is controlled to perform re-coating at the unqualified coating position.

9. The automatic coating system according to claim 8, characterized in that: The area to be coated is a rectangular area, and the image acquisition device includes five high-position cameras, which are respectively arranged above the four corners and one side of the rectangular area to acquire the images of the four corners and one side of the rectangular area.

10. The automatic coating system according to claim 8, characterized in that: The automatic coating system also includes: An alarm device is communicatively connected to the controller and is used to issue an alarm message when the number of re-application times exceeds a threshold.

Images