Automatic paint spraying method and device for vehicle lens

Abstract

The invention relates to an automatic paint spraying method and device for a vehicle lens, and relates to the technical field of automobile paint make-up. The appearance flatness of the rearview mirror is determined; when the appearance flatness of the rearview mirror does not fall into the reliable flatness range, obtaining rearview mirror coordinate information; determining position coordinates of a paint spraying area based on the rearview mirror coordinate information and the rearview mirror appearance flatness; determining current paint make-up area image data and target paint make-up area image data; comparing the current paint make-up area image data with the target paint make-up area image data to determine a current paint make-up color deviation value; when the current paint make-up color deviation value exceeds the maximum paint make-up area color deviation threshold value, the current paint make-up color is determined to execute paint make-up operation; and updating the current paint make-up color deviation value in real time in the process of executing the paint make-up operation so as to correct the current paint make-up color. The automatic paint spraying device has the effects of automatically positioning a paint spraying area and reducing manual color mixing chromatic aberration errors.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile paint repair, in particular to a vehicle mirror automatic paint spraying method and device. BACKGROUND

[0002] The vehicle rearview mirror lens is a core component for ensuring the safety of automobile driving, and the flatness and appearance of the mirror surface directly affect the stability of the reflection and the driver's field of view. The rearview mirror lens is usually processed by glass cutting process, and the side edge of the glass cutting lens is prone to unevenness, burrs, concave-convex defects and other problems, which not only reduces the appearance of the lens, but also causes glare interference due to irregular reflection of the side edge, affecting the driving safety; at the same time, the surface defects of the lens need to be repaired by spraying paint to unify the appearance of the paint surface and eliminate the reflection hazards.

[0003] In the prior art, the rearview mirror lens paint spraying and side edge defect repair are mainly achieved by technicians relying on naked eye observation to judge the flatness of the lens surface, manual positioning of the paint spraying and side edge repair area, and manual paint spraying according to personal experience; after the paint spraying is completed, the color difference and flatness effect are judged by naked eye, and if the color difference is obvious or the side edge is still uneven, the paint formula is adjusted manually for secondary spraying.

[0004] According to the related technology in the above, the manual paint spraying highly depends on the experience of engineers and the subjective judgment of naked eye, and the operation errors cannot effectively solve the problems of inaccurate paint color matching and uneven side edge. SUMMARY

[0005] In order to solve the problems of inaccurate paint color matching and subjective color difference judgment in manual paint repair, the present application provides a vehicle mirror automatic paint spraying method and device.

[0006] In the first aspect, the present application provides a vehicle mirror automatic paint spraying method, which adopts the following technical scheme: A vehicle mirror automatic paint spraying method, comprising: S1: in response to a paint repair signal, acquiring current rearview mirror image information; S2: determining the flatness of the outer surface of the rearview mirror based on the current rearview mirror image information; S3: when the flatness of the outer surface of the rearview mirror does not fall within a predetermined reliable flatness range, acquiring rearview mirror coordinate information; S4: determining the position coordinates of the paint spraying area based on the rearview mirror coordinate information and the flatness of the outer surface of the rearview mirror; S5: determining the current paint repair area image data and the target paint repair area image data by the position coordinates of the paint spraying area and the current rearview mirror image information; S6: comparing the current paint repair area image data and the target paint repair area image data to determine the current paint color deviation value; S7: when the current paint color deviation value exceeds the preset maximum paint area color deviation threshold, determining a current paint color based on the current paint color deviation value to perform a paint operation; S8: updating the current paint color deviation value in real time during the paint operation to correct the current paint color.

[0007] By adopting the above technical solutions, the paint color is automatically determined and corrected in real time, avoiding the problems of inaccurate paint color matching and uneven side caused by high dependence on technician experience and subjective judgment by naked eyes. The image information is used for flatness detection and color deviation comparison, realizing automatic positioning, color difference determination and real-time color correction of vehicle rearview mirror lenses based on surface flatness, solving the problems of inaccurate manual paint positioning, poor paint color matching and difficult color difference control, and improving the paint precision and stability.

[0008] Optionally, the method for determining the target paint area image data based on the paint area position coordinates and the current rearview mirror image information comprises: S50: obtaining adjacent area image data based on the target paint area image data, the adjacent area image data being divided into left adjacent area image data and right adjacent area image data; S51: obtaining a left color feature value corresponding to the left adjacent area image data and a right color feature value corresponding to the right adjacent area image data; S52: determining a current feature deviation value based on the left color feature value and the right color feature value; S53: when the current feature deviation value falls within a preset single-color paint range, determining the target paint area image data based on the adjacent area image data.

[0009] By adopting the above technical solutions, in the single-color paint rearview mirror paint scene, the target paint color is accurately matched by the color features of the adjacent areas, ensuring that the paint area is colorless and fused with the surrounding single-color paint surface.

[0010] Optionally, the method further comprises a method for determining the target paint area image data when the current feature value does not fall within the single-color paint range, the method comprising: S530: obtaining a left adjacent area image data color gradient feature and a right adjacent area image data color gradient feature; S531: determining a current color gradient difference value based on the left adjacent area image data and the right adjacent area image data; S532: when the current color gradient difference value falls within a preset gradient color gradient difference value range, determining a current gradient segment; S533: when the current gradient segment exists, determining a gradient direction and a gradient rate; S534: determining the target repainting region image data based on the color gradient feature of the left adjacent region image data, the color gradient feature of the right adjacent region image data, the gradient direction and the gradient rate.

[0011] By adopting the technical solution, for the gradient paint mirror, the target repainting region image data can be determined according to the color gradient feature of the adjacent region, the gradient direction and the gradient rate, the gradient rule is identified through the color gradient, and the target image is generated, so that the color fault is avoided after the gradient paint surface is sprayed, and the gradient effect is ensured to be coherent and natural.

[0012] Optionally, the method for determining the target repainting region image data when the current gradient segment does not exist also includes: S535: obtaining the main color feature of the mirror; S536: determining the current burr region based on the main color of the mirror and the color feature of the adjacent region image data; S537: performing a flushing operation based on the current burr region; S538: outputting a suspected scratch signal when the current burr region still exists after the flushing operation; S539: in response to the suspected scratch signal, excluding the current burr region to re-execute steps S530 to S534; S5390: when the current gradient segment does not exist and the suspected scratch signal exists, determining the target repainting region image data based on the main color feature of the mirror.

[0013] By adopting the technical solution, when the gradient segment does not exist and the suspected scratch exists, the target repainting region image data is determined based on the main color feature of the mirror, meanwhile, the interference factors such as the lens burr and impurities are automatically identified and excluded, the main color is sprayed when the gradient segment does not exist, the spray scene adaptability is improved, and the influence of the surface interference on the spray matching is excluded.

[0014] Optionally, the method for performing a scratch repainting operation also includes: S540: in response to the suspected scratch signal, obtaining the current burr region image; S541: determining the burr height based on the current burr region image; S542: when the burr height falls within a preset scratch range, performing a scratch repainting operation on the current burr region according to the target repainting region image data.

[0015] By adopting the technical solution, the lens scratch is determined according to the burr height, and the special repainting is performed, so that the repair of the lens scratch defect is realized, and the flaw processing pertinence is improved.

[0016] Optionally, the method also includes: S90: determining the flash particle density based on the current rearview mirror image information; S91: determining the pearl paint rearview mirror when the flash particle density falls within the preset pearl powder density range; S92: determining the flash particle orientation and the flash particle size through the current rearview mirror image information when the pearl paint rearview mirror exists; S93: determining the pearl paint touch-up area image data based on the flash particle density, the flash particle orientation and the flash particle size; S94: taking the pearl paint touch-up area image data as the target touch-up area image data and performing steps S6 to S8 when the pearl paint touch-up area image data exists.

[0017] By adopting the above technical solutions, the particle characteristics of the pearl paint rearview mirror are automatically identified and the corresponding touch-up image is generated, the pearl paint lens is adapted, and the original car pearl reflection quality is restored.

[0018] Optionally, the method further comprises: S95: determining the current color master combination scheme when the current touch-up color deviation value is less than the maximum touch-up area color deviation threshold; S96: obtaining the current vehicle model and the current rearview mirror appearance feature information; S97: forming the rearview mirror historical processing parameter based on the current vehicle model, the current rearview mirror appearance feature information and the current color master combination scheme; S98: determining the current rearview mirror associated number based on a preset incremental function; S99: recording the current rearview mirror associated number and the current color master combination scheme to the preset rearview mirror historical processing parameter library; S990: obtaining the touch-up vehicle model and the touch-up rearview mirror appearance feature information when the touch-up signal exists, and searching the rearview mirror historical processing parameter library based on the touch-up vehicle model and the touch-up rearview mirror appearance feature information to determine the matching rearview mirror associated number; S991: calling the color master combination scheme corresponding to the matching rearview mirror associated number as the target color master combination scheme, and performing the touch-up operation based on the target color master combination scheme.

[0019] By adopting the above technical solutions, the qualified color master combination scheme is stored in the historical library and can be directly reused, the repeated color matching process is reduced, and the spray painting efficiency and color consistency of the same type of rearview mirror are improved.

[0020] Optionally, the method further comprises a method of outputting a positioning calibration signal, which comprises: S70: obtaining the spray gun movement range and the current spray gun spraying point; S71: determining the spray gun spraying point coverable range based on the current spray gun spraying point and the spray gun movement range; S72: determining a minimum turning angle of the rearview mirror based on the sprayable range of the spray gun when the position coordinate of the paint spraying area does not fall within the sprayable range of the spray gun; S73: performing a turning operation of the rearview mirror based on the minimum turning angle of the rearview mirror, and re-determining the position coordinate of the paint spraying area; S74: determining a spray gun moving parameter based on the position coordinate of the paint spraying area, and controlling the spray gun to perform a spray gun moving operation according to the spray gun moving parameter; S75: outputting a positioning calibration signal after the spray gun moving operation is performed, and performing a touch-up operation.

[0021] By adopting the above technical solution, the method can automatically adjust the angle of the rearview mirror and the position of the spray gun according to the sprayable range of the spray gun, ensure that the paint spraying area can be accurately covered by the spray gun, improve the accuracy and stability of automatic paint spraying, ensure that the touch-up operation can be smoothly completed, avoid problems such as uneven touch-up or missed spraying caused by the fact that the spray gun cannot cover the paint spraying area, and improve the overall effect and quality of vehicle lens paint spraying.

[0022] In a second aspect, the present application provides a vehicle lens automatic paint spraying device, which adopts the following technical solution: A vehicle lens automatic paint spraying device, comprising a rack, a workbench for carrying a rearview mirror, a workpiece positioning and clamping assembly for fixing the rearview mirror, a glass pressing cylinder for pressing and fixing the rearview mirror, a spray gun driving assembly fixedly connected with the rack, and a spray gun fixedly connected with the spray gun driving assembly. The rack comprises a top frame, a side frame and a bottom support seat, and the top frame, the side frame and the bottom support seat form a semi-closed paint spraying operation chamber. The workbench is arranged in the paint spraying operation chamber, and the workbench is provided with two workpiece positioning portions; the workpiece positioning and clamping assembly is rotationally connected to the two workpiece positioning portions of the workbench; and the bottom end of the cylinder body of the glass pressing cylinder is fixedly connected with one end of the top frame close to the workbench.

[0023] By adopting the above technical solution, a stable working environment can be provided for vehicle lens paint spraying operation, the rearview mirror can be accurately fixed by the workpiece positioning portions and the workpiece positioning and clamping assembly of the workbench, and the glass pressing cylinder can be further pressed tightly to ensure that the position of the rearview mirror is stable during paint spraying. At the same time, the spray gun driving assembly can flexibly drive the spray gun to move, accurately paint different positions of the rearview mirror, improve the efficiency and quality of paint spraying, reduce errors caused by manual operation, better meet the needs of vehicle lens automatic paint spraying, and improve the automation level and effect of overall paint spraying operation.

[0024] Optionally, the spray gun driving assembly comprises a driving cylinder, a first connecting block fixedly connected with the driving cylinder, a fixed rod fixedly connected with the first connecting block, a first driving rod fixedly connected with the first connecting block, a second connecting block fixedly connected with the first driving rod, and a second driving rod in slidable connection with the second connecting block. The spray gun is fixedly connected with one end of the second driving rod away from the second connecting block.

[0025] By adopting the above technical scheme, the spray gun driving assembly can realize the movement and positioning of the spray gun. The driving cylinder provides power for the movement of the spray gun, and the power is transmitted to the first driving rod through the first connecting block. The first driving rod is fixedly connected with the second connecting block, so that the spray gun can move within a certain range along with the movement of the first driving rod. The second driving rod is in slidable connection with the second connecting block, which increases the flexibility of the movement of the spray gun and can adjust the position of the spray gun according to the actual paint spraying requirements.

[0026] To sum up, the present application has at least one of the following beneficial technical effects: 1. The image is automatically detected to reduce the dependence on experience and inaccurate visual judgment of manual paint spraying, improve the accuracy of paint spraying, and calculate the color difference and correct the color in real time; 2. Single-color paint, gradient paint, and pearl paint rearview mirrors can be automatically adapted, burrs and impurities can be identified and removed, scratches can be accurately determined and specially painted, and various defects such as unevenness and scratches on the side of the glass after cutting can be effectively repaired; 3. The angle of the rearview mirror and the position of the spray gun can be automatically adjusted to ensure accurate coverage of the paint spraying area, and the standard color master combination scheme can be stored and reused to reduce repeated color adjustment, improve the quality of paint spraying, and significantly improve the efficiency of batch paint spraying of the same type of rearview mirror. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is a structural schematic diagram of a vehicle lens automatic paint spraying device in an embodiment of the present application; Figure 2 is a structural schematic diagram of a spray gun driving assembly and a spray gun in an embodiment of the present application; Figure 3 is a flowchart of a vehicle lens automatic paint spraying method in an embodiment of the present application.

[0028] The parts denoted by the numbers in the above drawings are as follows: 1, rack; 11, top frame; 12, side frame; 13, bottom support seat; 2, workbench; 3, workpiece positioning and clamping assembly; 4, glass pressing cylinder; 5, spray gun driving assembly; 51, driving cylinder; 52, first connecting block; 53, fixed rod; 54, first driving rod; 55, second connecting block; 56, second driving rod; and 6, spray gun. DETAILED DESCRIPTION

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0030] This invention discloses an automatic vehicle lens painting device. (Refer to...) Figure 1 An automatic vehicle lens painting device includes a frame 1, a worktable 2, a workpiece positioning and clamping assembly 3, a glass pressing cylinder 4, a spray gun driving assembly 5, and a spray gun 6.

[0031] Reference Figure 1 The frame 1 includes a top frame 11, a side frame 12, and a bottom support 13. The top frame 11, the side frame 12, and the bottom support 13 form a semi-enclosed painting chamber for containing paint mist generated during the painting operation.

[0032] Reference Figure 1 Workbench 2 is placed within the painting chamber. Two workpiece positioning parts are located at the end of workbench 2 near the top frame 11. A drive motor is installed in the area corresponding to the workpiece positioning parts of workbench 2. The output shaft of the drive motor is fixedly connected to the end of the workpiece positioning and clamping assembly 3 near workbench 2. The end of the workpiece positioning and clamping assembly 3 away from the drive motor is used to clamp the rearview mirror to be painted. When the drive motor starts, it drives the workpiece positioning and clamping assembly 3 to rotate, thereby adjusting the angle of the rearview mirror to facilitate painting operations at different positions of the rearview mirror. The end of the top frame 11 near workbench 2 is fixedly connected to the bottom end of the cylinder body of the glass-pressing cylinder 4. The stroke of the glass-pressing cylinder 4 is 150mm, and the piston rod of the glass-pressing cylinder 4 faces towards workbench 2, used to press the rearview mirror to be painted.

[0033] Reference Figure 2 The spray gun drive assembly 5 is fixedly connected to the end of the top frame 11 away from the worktable 2. A sliding hole is provided at the end of the top frame 11 away from the worktable 2. The spray gun drive assembly 5 includes a drive cylinder 51, a first connecting block 52, a fixing rod 53, a first drive rod 54, a second connecting block 55, and a second drive rod 56. The output end of the drive cylinder 51 is fixedly connected to one end of the first connecting block 52. The first connecting block 52 has a first fixing hole. One end of the fixing rod 53 passes through the first fixing hole. Both ends of the fixing rod 53 are fixedly connected to the inner sidewall of the top frame 11. The first connecting block 52 has a second fixing hole. One end of the first drive rod 54 passes through the second fixing hole. The axial outer surface of the first drive rod 54 is fixedly connected to the wall of the fixing hole. The second connecting block 55 has a second sliding hole. One end of the second drive rod 56 passes through the second sliding hole. The second drive rod 56 is slidably connected to the second connecting block 55 through the second sliding hole.

[0034] Reference Figure 2The spray gun 6 is fixedly connected with one end of the second driving rod 56 away from the second connecting block 55. The spray gun 6 moves along the length direction of the side frame 12 through the driving cylinder 51, and moves along the length direction of the top frame 11 through the sliding of the second driving rod 56.

[0035] Based on the same inventive concept, the embodiment of the present application provides a vehicle mirror automatic paint spraying method. Referring to Figure 3 A vehicle mirror automatic paint spraying method comprises the following steps: Step S1: In response to a paint repair signal, current rearview mirror image information is acquired. The current rearview mirror image information refers to original image information containing the complete appearance of the rearview mirror to be repainted, which is captured by a camera in real time and includes color information and surface texture information of the rearview mirror. Step S2: The flatness of the outer surface of the rearview mirror is determined based on the current rearview mirror image information. The flatness of the outer surface of the rearview mirror refers to the smoothness and regularity of the outer surface of the rearview mirror, reflecting whether there are abnormalities such as concave, convex, and uneven side edges of the rearview mirror after glass cutting. The method for determining the flatness abnormal area is obtained by combining edge detection algorithm and reliable flatness range.

[0036] Step S3: When the flatness of the outer surface of the rearview mirror does not fall within the preset reliable flatness range, rearview mirror coordinate information is acquired. The reliable flatness range refers to a flatness range obtained through multiple experimental data. When the detected flatness of the outer surface of the rearview mirror exceeds this interval, it is determined that there is a flatness abnormality. The rearview mirror coordinate information refers to the absolute position parameters of the rearview mirror in the paint repair station coordinate system, specifically the three-dimensional coordinates of the rearview mirror. The paint repair station coordinate system refers to a coordinate system established with reference to the paint repair work area.

[0037] Step S4: The paint spraying area position coordinates are determined based on the rearview mirror coordinate information and the flatness of the outer surface of the rearview mirror.

[0038] The paint spraying area position coordinates refer to the specific position parameters of the area that needs to be painted based on the coordinates of the rearview mirror in the paint repair station coordinate system and the flatness of the outer surface.

[0039] Step S5: The current paint repair area image data and the target paint repair area image data are determined through the paint spraying area position coordinates and the current rearview mirror image information.

[0040] The current paint repair area image data refers to the original image data containing the complete state of the paint repair area, which is extracted from the current rearview mirror image information based on the paint area position coordinates. The target paint repair area image data refers to the ideal image data that needs to be achieved after paint repair, which is determined based on the paint area position coordinates and the normal appearance state of the rearview mirror. The determination method of the target paint repair area image data will be introduced in the subsequent content and will not be repeated here.

[0041] Step S6: Compare the current paint repair area image data with the target paint repair area image data to determine the current paint repair color deviation value.

[0042] The current paint repair color deviation value refers to the color difference quantization parameter calculated by the image comparison algorithm, which is used to reflect the color matching degree of the two.

[0043] Step S7: When the current paint repair color deviation value exceeds the preset maximum paint repair area color deviation threshold, determine the current paint repair color based on the current paint repair color deviation value to perform the paint repair operation.

[0044] The maximum paint repair area color deviation threshold refers to the upper limit of the deviation value that the human eye cannot identify the color difference, which is calibrated by a large number of artificial paint repair experiments. Specifically, the three components of the RGB color space corresponding to red, green and blue are less than 2 (the RGB color space takes values ranging from 0 to 255).

[0045] The current paint repair color refers to the specific color parameter that matches the target paint repair area color after adjustment and is suitable for the paint repair operation. The specific determination method of the current paint repair color is as follows: first, retrieve the preset color difference-color mother adjustment reference table, find the matching color mother adjustment parameter in the reference table based on the current paint repair color deviation value; then call the color adjustment algorithm to fuse and calculate the color mother adjustment parameter found and the original rearview mirror paint color parameter corresponding to the current paint repair area image data, adjust the specific parameters such as the color mother type and the addition ratio of the paint repair color, until the adjusted paint repair color is consistent with the color corresponding to the target paint repair area image data, and the current paint repair color is determined; finally, control the paint repair device to perform the paint repair operation according to the determined current paint repair color parameter. The color difference-color mother adjustment reference table refers to a database recording the color mother adjustment parameters corresponding to different paint repair color deviation values through multiple rearview mirror paint repair experiments. The color mother adjustment parameter refers to the specific adjustment specification of each type of color mother (such as basic color mother and adjustment color mother) that needs to be adjusted for the current paint repair color deviation, which is used to clearly define the adjustment standard and addition amount of each type of color mother.

[0046] Step S8: Update the current paint repair color deviation value in real time during the execution of the paint repair operation to correct the current paint repair color.

[0047] In the process of performing the touch-up operation by the touch-up equipment, image data of the touch-up area is collected in real time through the camera, and the current touch-up color deviation value is updated in real time by comparing with the target touch-up area image data, so that color deviation can be found and corrected in time.

[0048] The method for determining the target touch-up area image data based on the touch-up area position coordinates and the current rearview mirror image information comprises the following steps: Step S50: Obtain adjacent area image data based on the target touch-up area image data, and the adjacent area image data comprises left adjacent area image data and right adjacent area image data.

[0049] The adjacent area image data refers to the rearview mirror surface image data directly adjacent to the target touch-up area, which is determined by extending a preset width outward from the boundary coordinates of the target touch-up area image data. The left adjacent area image data refers to the rearview mirror surface image data located on the left side boundary of the target touch-up area and extending outward by a preset width. The right adjacent area image data refers to the rearview mirror surface image data located on the right side boundary of the target touch-up area and extending outward by a preset width. The preset width is 3 cm.

[0050] Step S51: Obtain left color feature values corresponding to the left adjacent area image data and right color feature values corresponding to the right adjacent area image data.

[0051] The left color feature values refer to pixel color change quantitative features obtained by performing gradient operation on the left adjacent area image data, and comprise gradient values and gradient direction distributions. The right color feature values refer to pixel color change quantitative features obtained by performing gradient operation on the right adjacent area image data, and comprise gradient values and gradient direction distributions.

[0052] Step S52: Determine a current feature deviation value based on the left color feature values and the right color feature values.

[0053] The current feature deviation value refers to a gradient value difference statistical result obtained by comparing the left color feature values with the right color feature values pixel by pixel and taking the average difference value. When the difference value is negative, the absolute value is processed.

[0054] Step S53: When the current feature deviation value falls within a preset single-color paint range, determine the target touch-up area image data based on the adjacent area image data.

[0055] The "monochrome paint range" refers to a characteristic value deviation interval determined through extensive experiments and data analysis. If the current characteristic deviation value falls within this range, it indicates that the color change of the target paint area and adjacent areas is relatively uniform, and it can be determined as a monochrome paint situation. If the current characteristic deviation value falls within the monochrome paint range, it means that the target paint area and adjacent areas belong to the same color system, and the image data of the target paint area can be directly determined based on the color characteristics of the image data of adjacent areas.

[0056] This includes a method for determining the image data of the target paint touch-up area when the current feature value does not fall within the range of a single-color paint. This method includes: Step S530: Obtain the color gradient features of the image data of the left adjacent region and the color gradient features of the image data of the right adjacent region.

[0057] Color gradient features of the left adjacent region image data refer to the spatial variation characteristics of color obtained by analyzing the color gradient of the left adjacent region image data, including information such as the magnitude and direction of the gradient. Similarly, color gradient features of the right adjacent region image data refer to the spatial variation characteristics of color obtained by analyzing the color gradient of the right adjacent region image data, also including information such as the magnitude and direction of the gradient. By analyzing these color gradient features, we can gain a deeper understanding of the patterns and trends of color changes in adjacent regions.

[0058] Step S531: Determine the current color gradient difference based on the image data of the left adjacent region and the image data of the right adjacent region.

[0059] The current color gradient difference refers to the difference obtained after quantifying and comparing the color gradient features of the image data in the left adjacent region and the color gradient features of the image data in the right adjacent region in terms of key dimensions such as gradient magnitude and gradient direction.

[0060] Step S532: When the current color gradient difference falls within the preset gradient color gradient difference range, determine the current gradient segment.

[0061] The gradient color difference range refers to a pre-defined interval used to determine whether the color change between the left and right adjacent image data regions constitutes a gradient transition. This range was derived through statistical analysis of a large amount of experimental data on gradient effects of different car models and paints.

[0062] The current gradient segment refers to the specific interval segment of color gradient transition identified from the color gradient features of the left adjacent region image data and the right adjacent region image data when the color gradient difference falls within the range of gradient color gradient difference. This interval segment covers the gradient range and gradient pattern of color from the left adjacent region to the right adjacent region.

[0063] If the current color gradient difference falls within the preset range of gradient color gradient differences, it indicates that the colors of the adjacent areas corresponding to the target paint repair area exhibit a gradual transition. At this point, based on the color change pattern of the current gradient segment and combining the color features of the image data from the left and right adjacent areas, interpolation calculations are performed on the color of the target paint repair area to determine its image data. The interpolation calculation is based on the continuity and trend of color within the gradient segment, selecting appropriate interpolation algorithms, such as linear interpolation or spline interpolation, to ensure that the color of the target paint repair area can naturally blend into the gradient effect of the adjacent areas.

[0064] Step S533: When a current gradient segment exists, determine the gradient direction and gradient rate.

[0065] The gradient direction refers to the spatial direction in which colors transition from one hue to another within the current gradient segment, such as a gradient from left to right or from top to bottom. It is determined by statistically analyzing the mainstream trend of gradient direction distribution.

[0066] Gradient rate refers to how quickly the color gradient value changes with the pixel position within the current gradient segment, reflecting the smoothness or steepness of the gradient color transition. It is calculated by collecting the gradient value change and the pixel distance, and then using the ratio between the two.

[0067] Step S534: Determine the target paint touch-up area image data based on the color gradient features of the left adjacent region image data, the color gradient features of the right adjacent region image data, the gradient direction, and the gradient rate.

[0068] When color gradient features of the left and right adjacent image data, along with the gradient direction and rate, exist, interpolation can be performed between the color gradient features of the left and right adjacent regions by combining this information. Guided by the gradient direction, the degree of color change for each pixel is determined according to the gradient rate, and the color value of each pixel within the target paint-touching area is calculated step by step.

[0069] This also includes a method for determining the image data of the target paint touch-up area when the current gradient segment does not exist. This method includes: Step S535: Obtain the main color features of the rearview mirror.

[0070] The main color characteristics of a rearview mirror refer to the various properties of the primary color presented by the mirror as a whole. These characteristics encompass the basic hue of the color. The hue determines the type of color, whether it is red, blue, green, etc.

[0071] Step S536: Determine the current burr area based on the color of the rearview mirror and the color features of the image data of the adjacent area.

[0072] The current spurious region refers to an area that significantly differs from the color characteristics of the rearview mirror's main subject and adjacent image data in a color feature comparison. This difference manifests as a sudden color change, irregular color patches, or color points that do not conform to the overall color trend. The current spurious region is determined using a color abrupt change threshold. The color abrupt change threshold is a critical value for color difference determined through extensive experiments and data analysis, used to judge whether a color change constitutes an abnormal abrupt change. When the color difference between a region and the color characteristics of the rearview mirror's main subject and adjacent image data exceeds this threshold, it is identified as a spurious region.

[0073] Step S537: Perform a flushing operation based on the current burr area.

[0074] The rinsing operation refers to using the spray gun 6 to rinse the current burr area to remove impurities, stains, or burrs that may cause abnormal color.

[0075] Step S538: If the current burr area still exists after the rinsing operation, output a suspected scratch signal.

[0076] A suspected scratch signal is a signal emitted when a burr area is detected to still exist after a rinsing operation, indicating that there may be scratches that are difficult to remove by rinsing.

[0077] If the burr area still exists after rinsing, it indicates that the abnormal color of the rearview mirror surface is not caused by simple impurities, stains or burrs, but is likely due to deeper scratches.

[0078] Step S539: In response to a suspected scratch signal, remove the current burr area to re-execute steps S530 to S534.

[0079] When a suspected scratch signal is present, it indicates that the abnormal color on the rearview mirror surface is caused by a scratch, and the color characteristics of the current burr area cannot accurately reflect the normal condition of the repainted area. In this case, the current burr area is removed from the image data, and the process restarts from step S530. The color gradient characteristics of the left and right adjacent image data are reacquired, and the current color gradient difference is recalculated to determine if it falls within a preset gradient color gradient difference range. If it falls within this range, the current gradient segment is determined, followed by the gradient direction and gradient rate. Finally, the target repainted area image data is determined based on the color gradient characteristics of the left and right adjacent image data, the gradient direction, and the gradient rate.

[0080] Step S5390: When there is no current gradient segment and there is a suspected scratch signal, determine the image data of the target paint repair area based on the color characteristics of the rearview mirror.

[0081] When there is no current gradient segment and a suspected scratch signal exists, it indicates that the rearview mirror surface color, even after excluding the influence of scratches, does not exhibit a gradient pattern. Therefore, the main color feature of the rearview mirror is directly used as the color reference for the target paint repair area image data. If the rearview mirror surface has multiple main colors, the target paint repair area image data is determined based on the main colors of adjacent areas.

[0082] This also includes a method for performing scratch repair painting, which includes: Step S540: In response to a suspected scratch signal, acquire an image of the current burr area.

[0083] The current spurious region image refers to the image data captured from the current spurious region, containing complete information about the current spurious region. This image data records detailed information such as the height and color characteristics of the spurious region.

[0084] When a suspected scratch signal is present, it indicates that there may be scratches on the surface of the rearview mirror. In this case, it is necessary to obtain an image of the current burr area to determine whether the current burr area is caused by a scratch.

[0085] Step S541: Determine the burr height based on the current burr region image.

[0086] The burr height refers to the height of the bulge relative to the normal rearview mirror surface. The burr height can be calculated by processing the image of the burr area using stereo vision measurement.

[0087] Step S542: When the burr height falls within the preset scratch range, perform scratch repair painting on the current burr area according to the target repair area image data.

[0088] Scratch repair painting refers to the process of repairing scratches by applying paint to the scratched area after determining that the height of the burr falls within the scratch area, based on the current paint color determined by the image data of the target repair area.

[0089] The scratch range refers to the height interval determined through extensive experiments and data analysis to judge whether the burr height represents a scratch. When the burr height falls within this scratch range, it indicates that the current burr area is a scratch area, and a paint repair operation needs to be performed on the scratch in the current burr area according to the image data of the target paint repair area.

[0090] This also includes: Step S90: Determine the flash particle density based on the current rearview mirror image information.

[0091] Flash particle density refers to the number of pearlescent particles per unit area obtained by using an image texture feature recognition algorithm to count the number of feature points corresponding to flash particles within a unit pixel area, and then combining the pixel conversion relationship of the 3D vision sensor with the actual size.

[0092] Step S91: When the density of the glitter particles falls within the preset pearlescent powder density range, determine the pearlescent paint rearview mirror.

[0093] The pearlescent powder density range refers to the range of glitter particle density that is pre-calibrated through numerous pearlescent paint sample experiments and used to distinguish pearlescent paint from monochrome paint. A pearlescent paint rearview mirror refers to a rearview mirror where the glitter particle density of the target paint touch-up area falls within the pearlescent powder density range, and the paint layer on the mirror surface contains flaky pearlescent powder particles.

[0094] Step S92: When a pearlescent paint rearview mirror is present, determine the orientation and particle size of the flash particles using the current rearview mirror image information.

[0095] The orientation of the pearlescent particles refers to the angle distribution range between the long axis direction of the flaky pearlescent powder particles, identified by a pixel edge fitting algorithm based on the current rearview mirror image information, and the preset baseline of the rearview mirror, which determines the reflective texture of the pearlescent paint. Specifically, the pixel edge fitting algorithm here is a combination of image preprocessing, Canny edge detection, contour extraction, and least-squares ellipse fitting. This combination algorithm is composed of conventional techniques in the field and will not be elaborated upon further.

[0096] The particle size of the pearlescent powder refers to the average diameter of the pearlescent powder particles calculated based on the current rearview mirror image information and the conversion relationship between pixel size and actual size. The particle size directly affects the gloss and smoothness of the pearlescent paint.

[0097] Step S93: Determine the image data of the pearlescent paint repair area based on the glitter particle density, glitter particle orientation, and glitter particle size.

[0098] The target pearlescent paint formulation parameters refer to the set of formulation information determined by retrieving a preset pearlescent paint standard formulation database based on the density, orientation, and particle size parameters of the glitter particles. The core parameters include the type and proportion of the base color masterbatch, the mass ratio of pearlescent powder, and the selection parameters for pearlescent powder particle size. Here, the pearlescent paint standard formulation database refers to a standardized relational database established based on a large amount of pearlescent paint data, storing standard information for pearlescent paints of different car models and color schemes. This database records in detail the formulations of various pearlescent paints under different glitter particle densities, orientations, and particle sizes. It can accurately find matching formulation information based on input particle parameters and output the corresponding type and mass ratio of the base color masterbatch, the pearlescent powder addition ratio, and the particle size selection.

[0099] Step S94: When pearlescent paint repair area image data exists, use the pearlescent paint repair area image data as the target paint repair area image data, and execute steps S6 to S8.

[0100] When pearlescent paint repair area image data exists, it indicates that the vehicle rearview mirror is painted with pearlescent paint. At this time, the pearlescent paint repair area image data is used as the target paint repair area image data to execute steps S6 to S8.

[0101] This also includes: Step S95: When the current paint color deviation value is less than the maximum paint area color deviation threshold, determine the current color masterbatch combination scheme.

[0102] The current color masterbatch combination scheme refers to the final, stable color masterbatch formula scheme that meets the quality requirements of the touch-up paint after the color deviation value of the touch-up area meets the standard. If it is a pearlescent paint rearview mirror, this scheme is the pearlescent color masterbatch combination scheme; if it is a monochrome or gradient paint rearview mirror, this scheme is the ordinary color masterbatch combination scheme, which is the core parameter for subsequent historical reuse. If the current touch-up paint color deviation value is less than the maximum touch-up area color deviation threshold, it means that the difference between the actual color of the touched-up area and the expected color of the touched-up area is within the range imperceptible to the human eye. The color matching accuracy of the current color masterbatch combination scheme (including the pearlescent color masterbatch scheme) meets the standard, the touch-up effect is qualified, and it can be retained and reused as a historical parameter.

[0103] Step S96: Obtain the current vehicle model and the current rearview mirror appearance features.

[0104] The current vehicle model refers to the specific specifications of the vehicle to be repainted, including the vehicle brand, model series, production year, and configuration version, which is used as the primary matching condition for historical parameter retrieval.

[0105] The current rearview mirror appearance feature information refers to the set of rearview mirror appearance attributes strongly correlated with the paint repair formula, specifically the paint type (single-color paint, pearlescent paint, and gradient paint). The current vehicle model is manually entered into the system before the paint repair operation. The current rearview mirror appearance feature information is obtained by analyzing the current rearview mirror image information to determine the corresponding paint type.

[0106] Step S97: Generate historical processing parameters for the rearview mirror based on the current vehicle model, the current appearance feature information of the rearview mirror, and the current color masterbatch combination scheme.

[0107] The rearview mirror historical processing parameters refer to the standardized data units formed by integrating the current vehicle model, the current rearview mirror appearance features, and the current color master combination scheme, which facilitates subsequent retrieval and reuse.

[0108] Step S98: Determine the current rearview mirror association number based on a preset incrementing function.

[0109] An incrementing function is a pre-defined auto-incrementing sequence function used to generate a unique rearview mirror association number.

[0110] The current rearview mirror association number refers to a code generated by an incrementing function to uniquely identify a set of historical processing parameters of the rearview mirror. It serves as the core index of the historical processing parameter library of the rearview mirror, enabling fast retrieval and association of historical parameters.

[0111] Step S99: Record the current rearview mirror association number and the current color master combination scheme to the preset rearview mirror historical processing parameter library.

[0112] The rearview mirror history processing parameter library is a standardized relational database built from multiple rearview mirror repainting data. It stores the history processing parameters of all qualified repainting scenarios of the rearview mirror, indexed by the current rearview mirror association number.

[0113] Step S990: When a paint repair signal is present, obtain the vehicle model and the appearance feature information of the paint repaired rearview mirror, and search the rearview mirror historical processing parameter library based on the paint repaired vehicle model and the appearance feature information of the paint repaired rearview mirror to determine the matching rearview mirror association number.

[0114] The vehicle model for paint repair refers to the specification identification information corresponding to the vehicle that currently triggers the paint repair signal. It is consistent with the current vehicle model definition and is used as the initial matching condition for searching the historical parameter database.

[0115] The appearance feature information of a repainted rearview mirror refers to the set of appearance attributes exhibited by the rearview mirror corresponding to the current rearview mirror model, which is similar to the current rearview mirror appearance feature information. It mainly refers to the type of paint.

[0116] The matching rearview mirror association number refers to the association number retrieved from the rearview mirror historical processing parameter database based on the vehicle model and appearance characteristics of the repainted rearview mirror, corresponding to the historical processing parameters of the same model of rearview mirror.

[0117] Step S991: Retrieve the color masterbatch combination scheme corresponding to the matching rearview mirror association number, and use it as the target color masterbatch combination scheme. Perform the touch-up paint operation based on the target color masterbatch combination scheme.

[0118] The target color masterbatch combination scheme refers to a color masterbatch formula scheme suitable for the current painting scenario, matched from the historical processing parameter database based on the vehicle model and the appearance characteristics of the rearview mirror being painted. If the vehicle being painted has a pearlescent paint rearview mirror, this scheme is a pearlescent color masterbatch combination scheme that meets the requirements of pearlescent paint painting, including parameters such as the appropriate type and ratio of base color masterbatch, the mass ratio of pearlescent powder added, and the particle size selection; if the vehicle is painted with a single color or gradient paint, then it is the corresponding ordinary color masterbatch combination scheme.

[0119] This also includes a method for outputting a positioning calibration signal, the method comprising: Step S70: Obtain the spray gun movement range and the current spray gun spray point.

[0120] The spray gun's movement range refers to the maximum spatial area that it can move within the painting operation chamber under the drive of the spray gun drive assembly 5, which is limited by hardware structural parameters such as the stroke of the drive cylinder 51 and the sliding distance of the second drive rod 56.

[0121] The current spray gun spray point refers to the spatial coordinate point where the nozzle of spray gun 6 is currently located, which is used to spray paint onto the rearview mirror.

[0122] Step S71: Determine the coverage area of ​​the spray gun spray point based on the current spray gun spray point and the spray gun movement range.

[0123] The spray gun's spray point coverage area refers to the rearview mirror surface area that the spray gun 6 can directly spray paint onto, determined by taking the current spray gun spray point as a reference and combining the spray gun's movement range with the effective spray radius of the spray gun 6.

[0124] Step S72: When the position coordinates of the paint spraying area do not fall within the coverage area of ​​the spray gun spray point, determine the minimum rotation angle of the rearview mirror based on the coverage area of ​​the spray gun spray point.

[0125] The minimum rotation angle of the rearview mirror refers to the minimum angle value that the workpiece positioning and clamping assembly 3 needs to rotate to ensure that the position coordinates of the paint spraying area fall within the coverage area of ​​the spray gun spray point. It is calculated from the relative positional relationship between the position coordinates of the paint spraying area and the coverage area of ​​the spray gun spray point.

[0126] When the coordinates of the area to be painted do not fall within the coverage area of ​​the spray gun's spray point, it means that the current spray gun 6 cannot directly spray the area to be painted, and the position of the area to be painted needs to be adjusted by rotating the rearview mirror.

[0127] Step S73: Perform a rearview mirror rotation operation based on the minimum rotation angle of the rearview mirror, and redetermine the position coordinates of the paint spraying area.

[0128] The rearview mirror rotation operation refers to the operation of starting the drive motor, causing the workpiece positioning and clamping assembly 3 to rotate at the minimum rotation angle of the rearview mirror, thereby adjusting the placement angle of the rearview mirror and moving the painting area to the range that the spray gun spray point can cover.

[0129] Step S74: Determine the spray gun movement parameters based on the position coordinates of the paint spraying area, and control the spray gun 6 to perform the spray gun movement operation according to the spray gun movement parameters.

[0130] The spray gun movement parameters refer to the direction, distance, speed, and other parameters that the spray gun drive assembly 5 needs to drive the spray gun 6 to move in order to make the spray gun 6 accurately aligned with the updated coordinates of the painting area. These parameters are calculated from the updated coordinates of the painting area and the current coordinates of the spray gun 6.

[0131] The spray gun movement operation refers to the operation in which the spray gun drive assembly 5 drives the spray gun 6 to move along the length direction of the side frame 12 and the length direction of the top frame 11 according to the spray gun movement parameters, until the spray gun spray point is aligned with the spraying area.

[0132] Step S75: After performing the spray gun movement operation, output a positioning calibration signal and perform a touch-up paint operation.

[0133] The positioning calibration signal is a calibration completion prompt signal output by the system after the spray gun 6 has completed its movement, the rearview mirror has completed its angle adjustment, and the spray gun's spray point has been aligned. It is used to trigger the normal execution of subsequent touch-up painting operations.

[0134] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An automatic painting method for vehicle lenses, characterized in that, include: S1: In response to the paint touch-up signal, obtain the current rearview mirror image information; S2: Determine the flatness of the rearview mirror surface based on the current rearview mirror image information; S3: When the flatness of the rearview mirror surface does not fall within the preset reliable flatness range, obtain the rearview mirror coordinate information; S4: Determine the coordinates of the paint spraying area based on the rearview mirror coordinate information and the flatness of the rearview mirror surface; S5: Determine the current paint repair area image data and the target paint repair area image data by using the paint spraying area location coordinates and the current rearview mirror image information; S6: Compare the current paint repair area image data with the target paint repair area image data to determine the current paint color deviation value; S7: When the current paint color deviation value exceeds the preset maximum paint area color deviation threshold, determine the current paint color based on the current paint color deviation value and perform the paint repair operation; S8: Update the current paint color deviation value in real time during the paint touch-up operation to correct the current paint color.

2. The automatic painting method for vehicle lenses according to claim 1, characterized in that, Methods for determining the image data of the target paint repair area using the location coordinates of the paint spraying area and the current rearview mirror image information include: S50: Obtain adjacent region image data based on the target paint touch-up area image data, wherein the adjacent region image data is divided into left adjacent region image data and right adjacent region image data; S51: Obtain the left color feature value corresponding to the image data of the left adjacent region and the right color feature value corresponding to the image data of the right adjacent region; S52: Determine the current feature deviation value based on the left and right color feature values; S53: When the current feature deviation value falls within the preset range of monochrome paint, determine the target paint touch-up area image data based on the image data of adjacent areas.

3. The automatic painting method for vehicle lenses according to claim 2, characterized in that, It also includes a method for determining the image data of the target repainting area when the current feature value does not fall within the range of a single-color paint, the method comprising: S530: Obtain the color gradient features of the image data of the left adjacent region and the color gradient features of the image data of the right adjacent region; S531: Determine the current color gradient difference based on the image data of the left adjacent region and the image data of the right adjacent region; S532: When the current color gradient difference falls within the preset gradient color gradient difference range, determine the current gradient segment; S533: When a current transition segment exists, determine the transition direction and transition rate; S534: Determine the target paint touch-up area image data based on the color gradient features of the left adjacent region image data, the color gradient features of the right adjacent region image data, the gradient direction, and the gradient rate.

4. The automatic painting method for vehicle lenses according to claim 3, characterized in that, It also includes a method for determining the image data of the target paint touch-up area when the current gradient segment does not exist, the method comprising: S535: Obtain the main color features of the rearview mirror; S536: Determine the current burr area based on the color features of the main body color of the rearview mirror and the image data of adjacent areas; S537: Perform a flushing operation based on the current burr area; S538: When the current burr area still exists after the rinsing operation, output a suspected scratch signal; S539: In response to a suspected scratch signal, remove the current burr area to re-execute steps S530 to S534; S5390: When there is no current gradient segment and there is a suspected scratch signal, determine the image data of the target paint repair area based on the color characteristics of the rearview mirror.

5. The automatic painting method for vehicle lenses according to claim 4, characterized in that, It also includes a method for performing scratch repair painting, which includes: S540: In response to a suspected scratch signal, acquire an image of the current burr area; S541: Determine the burr height based on the current burr region image; S542: When the burr height falls within the preset scratch range, perform scratch repair painting operation on the current burr area according to the target repair area image data.

6. The automatic painting method for vehicle lenses according to claim 1, characterized in that, Also includes: S90: Determine the density of flash particles based on the current rearview mirror image information; S91: When the density of the glitter particles falls within the preset range of pearlescent powder density, the pearlescent paint rearview mirror is confirmed; S92: When a pearlescent paint rearview mirror is present, determine the orientation and particle size of the flash particles using the current rearview mirror image information; S93: Determine image data of pearlescent paint repair area based on flash particle density, flash particle orientation and flash particle size; S94: When pearlescent paint repair area image data exists, use the pearlescent paint repair area image data as the target paint repair area image data, and execute steps S6 to S8.

7. The automatic painting method for vehicle lenses according to claim 6, characterized in that, Also includes: S95: When the current paint touch-up color deviation value is less than the maximum paint touch-up area color deviation threshold, determine the current color masterbatch combination scheme; S96: Obtain information on the current vehicle model and the current rearview mirror's appearance features; S97: Based on the current vehicle model, current rearview mirror appearance features, and current color masterbatch combination scheme, the historical processing parameters of the rearview mirror are generated. S98: Determine the current rearview mirror association number based on a preset incrementing function; S99: Record the current rearview mirror association number and the current color master combination scheme to the preset rearview mirror history processing parameter library; S990: When a paint repair signal is present, obtain the vehicle model and the appearance feature information of the paint repaired rearview mirror, and search the rearview mirror historical processing parameter library based on the paint repaired vehicle model and the appearance feature information of the paint repaired rearview mirror to determine the matching rearview mirror association number. S991: Retrieve the color masterbatch combination scheme corresponding to the matching rearview mirror association number, and use it as the target color masterbatch combination scheme. Perform a touch-up paint operation based on the target color masterbatch combination scheme.

8. The automatic painting method for vehicle lenses according to claim 1, characterized in that, It also includes a method for outputting a positioning calibration signal, the method comprising: S70: Get the spray gun movement range and current spray gun spray point; S71: Determine the coverage area of ​​the spray gun spray point based on the current spray gun spray point and the spray gun movement range; S72: When the coordinates of the paint spraying area do not fall within the coverage area of ​​the spray gun spray point, determine the minimum rotation angle of the rearview mirror based on the coverage area of ​​the spray gun spray point. S73: Perform a rearview mirror rotation operation based on the minimum rotation angle of the rearview mirror, and redetermine the position coordinates of the paint spraying area; S74: Determine the spray gun movement parameters based on the position coordinates of the paint spraying area, and control the spray gun (6) to perform the spray gun movement operation according to the spray gun movement parameters; S75: After performing the spray gun movement operation, output a positioning calibration signal and perform a touch-up paint operation.

9. An automatic vehicle lens painting device, applied to the automatic vehicle lens painting method as described in any one of claims 1 to 8, characterized in that: Includes a frame (1), a worktable (2) for carrying the rearview mirror, a workpiece positioning and clamping assembly (3) for fixing the rearview mirror, a glass pressing cylinder (4) for pressing and fixing the rearview mirror, a spray gun drive assembly (5) fixedly connected to the frame (1), and a spray gun (6) fixedly connected to the spray gun drive assembly (5). The frame (1) includes a top frame (11), a side frame (12) and a bottom support (13), which together form a semi-enclosed painting chamber. The workbench (2) is located in the painting operation chamber. The workbench (2) is provided with two workpiece positioning parts. The workpiece positioning clamping assembly (3) is rotatably connected to the two workpiece positioning parts of the workbench (2). The bottom end of the cylinder body of the glass pressing cylinder (4) is fixedly connected to the end of the top frame (11) near the workbench (2).

10. The automatic vehicle lens painting device according to claim 9, characterized in that: The spray gun drive assembly (5) includes a drive cylinder (51), a first connecting block (52) fixedly connected to the drive cylinder (51), a fixing rod (53) fixedly connected to the first connecting block (52), a first drive rod (54) fixedly connected to the first connecting block (52), a second connecting block (55) fixedly connected to the first drive rod (54), and a second drive rod (56) slidably connected to the second connecting block (55). The spray gun (6) is fixedly connected to the end of the second drive rod (56) away from the second connecting block (55).

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