Intelligent grinding and spraying system

Abstract

The invention provides an intelligent polishing and spraying system which comprises a recognition module, a database module, a multi-process execution module and a monitoring module, the recognition module comprises a plurality of sensors and is used for cooperatively collecting physical information of the surface of a workpiece, and the database module comprises a data processing unit, a defect analysis unit and a control unit. The data processing unit is connected with the recognition module and used for receiving the physical information and constructing a three-dimensional model of the surface of the workpiece, a standard database is preset in the defect analysis unit, and the defect type and position of the surface of the workpiece are recognized and analyzed in combination with the three-dimensional model to generate a repair path for the defect; according to the system, the recognition module, the database module, the multi-process execution module and the monitoring module are integrated, automatic operation is achieved, the defect recognition and repair quality can be remarkably improved, the multi-process execution module can be compatible with multiple repair procedures, actual use is convenient, and meanwhile the system cost is reduced.

Description

Technical Field

[0001] This invention relates to an intelligent grinding and spraying system. Background Technology

[0002] With socio-economic development and rising consumption levels, the market's demands for product appearance quality are becoming increasingly stringent. However, current traditional spraying operations have significant limitations: First, manual spraying is inefficient, and the spraying effect is highly dependent on worker experience, making it difficult to guarantee quality stability; second, automated equipment with fixed trajectories cannot dynamically adjust parameters when dealing with complex curved workpieces, easily leading to uneven spraying; third, sheet metal shaping, puttying, sanding, and paint repair are currently mostly done in separate, independent steps, with loose process connections and reliance on manual judgment, which not only prolongs the manufacturing cycle but also easily causes the accumulation of errors at each stage, seriously affecting the final repair effect and product consistency. Therefore, existing technologies still need improvement and development. Summary of the Invention

[0003] To address the shortcomings mentioned above, this invention provides an intelligent grinding and spraying system.

[0004] To achieve the above objectives, the present invention provides an intelligent grinding and spraying system, including an identification module, a database module, a multi-process execution module, and a monitoring module. The identification module includes multiple sensors for collecting physical information about the workpiece surface. The database module includes a data processing unit, a defect analysis unit, and a control unit. The data processing unit is connected to the identification module and is used to receive physical information and construct a three-dimensional model of the workpiece surface. The defect analysis unit has a preset standard database and combines it with the three-dimensional model to identify and analyze the defect types and locations on the workpiece surface and generate repair paths for the defects. The control unit generates and outputs control signals based on the repair paths or external feedback signals. A multi-process execution module is connected to a database module. The multi-process execution module includes a conversion component and a shaping execution unit, a puttying execution unit, a sanding execution unit, and a spraying execution unit installed on the conversion component. The conversion component switches to the corresponding execution unit under the control of the control unit, and the corresponding execution unit performs the corresponding process under the control of the control unit. The monitoring module, corresponding to the multi-process execution module, is used to monitor the processes completed by each execution unit in real time, including the shaping unit, puttying unit, sanding unit, and spraying unit, and feeds the monitoring data back to the control unit to form a closed-loop control.

[0005] Furthermore, it also includes a workpiece transport module, which includes a transport robotic arm and a clamp located at the end of the transport robotic arm. The clamp is used to clamp the workpiece, and the transport robotic arm is used to move the clamped workpiece from the identification module to the multi-process execution module and cooperate with the multi-process execution module under the control of the control unit.

[0006] Furthermore, the sensors include a 3D laser scanner and a high-precision camera.

[0007] Furthermore, the shaping execution unit includes a shaping servo motor and a mechanical straightening head. The fixed end of the shaping servo motor is connected to the conversion component, and the mechanical straightening head is connected to the output end of the shaping servo motor and is driven by the shaping servo motor to apply force to the deformation area of ​​the workpiece.

[0008] Furthermore, the putty application unit includes a scraper, an adjustment drive, and an extrusion assembly. One end of the scraper is connected to a conversion component, and both ends of the adjustment drive are connected to the scraper and the conversion component respectively to adjust the angle between the scraper and the conversion component. The extrusion assembly is adjacent to the scraper and includes a material tube, an extrusion nozzle, an extrusion rod, and an extrusion drive. The material tube is connected to the conversion component and one end is connected to the extrusion nozzle. One end of the extrusion rod is located inside the material tube, and the other end is connected to the output end of the extrusion drive. The extrusion drive is used to extrude the repair material in the material tube to the extrusion nozzle.

[0009] Furthermore, the grinding execution unit includes a multi-axis robotic arm, a frequency conversion grinding assembly, and a dust recovery assembly. One end of the multi-axis robotic arm is connected to a conversion component. The frequency conversion grinding assembly is located at the end of the multi-axis robotic arm and includes a frequency conversion motor and a grinding head. The grinding head is connected to the output end of the frequency conversion motor. The dust recovery assembly corresponds to the frequency conversion grinding assembly and is located at the end of the multi-axis robotic arm. The dust recovery assembly includes a cover, an air pump, and a dust collection box. The cover at least partially covers the grinding head. The air pump is connected to the cover through an air pipe. The dust collection box is located between the cover and the air pump to separate and recover dust.

[0010] Furthermore, the multi-axis robotic arm is a six-axis robotic arm, the grinding head is a grinding wheel, and the cover is connected to the end of the multi-axis robotic arm via a flexible bracket.

[0011] Furthermore, the spraying execution unit includes a spray gun robotic arm and a spray gun assembly. The spray gun robotic arm is connected to a conversion component. The spray gun assembly is located at the end of the spray gun robotic arm. The spray gun assembly includes a spray gun and a wrench control component. The spray gun inlet is connected to a material box via a material pipe, and the air inlet is connected to an air pump via an air supply pipe. The output end of the wrench control component is connected to the wrench of the spray gun to control the start and stop of the spray gun.

[0012] Furthermore, the material bin contains water-based or oil-based paint.

[0013] Furthermore, the monitoring module includes a surface vision sensor.

[0014] The advantages of this invention over the prior art are as follows: the system of this invention integrates the identification module, database module, multi-process execution module and monitoring module to realize automated operation, which can significantly improve the quality of defect identification and repair; and the multi-process execution module is compatible with a variety of repair procedures, which is convenient to use and reduces system costs. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the system architecture of an intelligent grinding and spraying system according to the present invention. Detailed Implementation

[0016] like Figure 1 As shown, an intelligent grinding and spraying system according to an embodiment of the present invention includes an identification module, a database module, a workpiece transport module, a multi-process execution module, and a monitoring module. These modules are integrated to achieve fully automated operation throughout the entire process.

[0017] Furthermore, such as Figure 1 As shown, the identification module in this embodiment includes multiple sensors for cooperating in collecting physical information of the workpiece surface; specifically, the sensors in the identification module include a 3D laser scanner and a high-precision camera. The 3D laser scanner is used to quickly acquire the three-dimensional data of the workpiece, and the high-precision camera can quickly acquire detailed texture information of the workpiece surface.

[0018] Furthermore, such as Figure 1 As shown, the database module in this embodiment includes a data processing unit, a defect analysis unit, and a control unit. The data processing unit is connected to the identification module and is used to receive physical information and construct a three-dimensional model of the workpiece surface. The defect analysis unit has a preset standard database and combines it with the three-dimensional model to identify and analyze the defect types and locations on the workpiece surface, and generate repair paths for the defects. The control unit generates and outputs control signals based on the repair paths or external feedback signals. The standard database contains appearance data of various workpieces, which are manually or AI-inputted.

[0019] Furthermore, such as Figure 1 As shown, the workpiece transport module in this embodiment includes a transport robotic arm and a clamp located at the end of the transport robotic arm. The clamp is used to clamp the workpiece, and the transport robotic arm is used to move the clamped workpiece from the identification module to the multi-process execution module and cooperate with the multi-process execution module under the control of the control unit.

[0020] Furthermore, such as Figure 1As shown, in this embodiment, the multi-process execution module is connected to the database module. The multi-process execution module includes a conversion component and shaping execution units, puttying execution units, sanding execution units, and spraying execution units installed on the conversion component. The conversion component switches to the corresponding execution units under the control of the control unit, and the corresponding execution units perform the corresponding processes under the control of the control unit. The multi-process execution module is compatible with multiple repair processes. In actual use, the entire process flow can be a series of processes of shaping, puttying, sanding, and spraying, or a series of processes of puttying, sanding, and spraying, or other combinations of processes. In addition, a monitoring module is set up corresponding to the multi-process execution module. It includes a surface vision sensor for real-time monitoring of the processes completed by each execution unit in the shaping, puttying, sanding, and spraying execution units, and feeds the data generated by the monitoring back to the control unit to form a closed-loop control. The closed-loop control realizes precise control of the system, improves the stability and accuracy of the system, reduces manual intervention, and reduces operating costs.

[0021] Specifically, the shaping execution unit in this embodiment includes a shaping servo motor and a mechanical straightening head. The fixed end of the shaping servo motor is connected to the conversion component, and the mechanical straightening head is connected to the output end of the shaping servo motor and is driven by the shaping servo motor to apply force to the deformed area of ​​the workpiece to perform the shaping process. The shaping process is as follows: the mechanical straightening head contacts and abuts against the deformed part of the workpiece, and applies force to the deformed part through the output power of the servo motor so that the workpiece undergoes plastic deformation according to a preset time.

[0022] Specifically, the putty application unit in this embodiment includes a scraper, an adjustment drive, and an extrusion assembly. One end of the scraper is connected to a conversion component. Both ends of the adjustment drive are connected to the scraper and the conversion component respectively to adjust the angle between the scraper and the conversion component, thereby controlling the thickness of the repair layer. The extrusion assembly is adjacent to the scraper and includes a material tube, an extrusion nozzle, an extrusion rod, and an extrusion drive. The material tube is connected to the conversion component and one end is connected to the extrusion nozzle. One end of the extrusion rod is located inside the material tube, and the other end is connected to the output end of the extrusion drive. The extrusion drive is used to extrude the repair material in the material tube to the extrusion nozzle. The putty application process is as follows: the control unit controls the repair material output rate of the extrusion assembly and the movement of the transport robotic arm to apply the repair material along the repair path of the defect. Then, the control unit controls the scraper angle and the movement of the transport robotic arm to apply and compact the repair material, which is still in a plastic state, and adjust the putty thickness.

[0023] Specifically, the grinding execution unit in this embodiment includes a multi-axis robotic arm, a frequency conversion grinding component, and a dust collection component. One end of the multi-axis robotic arm is connected to a conversion component. The frequency conversion grinding component is located at the end of the multi-axis robotic arm and includes a frequency conversion motor and a grinding head. The grinding head is connected to the output end of the frequency conversion motor. The dust collection component corresponds to the frequency conversion grinding component and is located at the end of the multi-axis robotic arm. The dust collection component includes a cover, an air pump, and a dust collection box. The cover at least partially covers the grinding head. The air pump is connected to the cover through an air pipe. The dust collection box is located between the cover and the air pump. The dust is separated and recovered. The multi-axis robotic arm is a six-axis robotic arm, and the grinding head is a grinding wheel. The cover is connected to the end of the multi-axis robotic arm through a flexible bracket to adjust the position of the cover relative to the grinding head. The grinding process is as follows: the control unit controls the start of the dust recovery component and the frequency conversion grinding component. When the grinding head reaches the preset speed, the control unit controls the multi-axis robotic arm and the transport robotic arm to make the grinding head contact the workpiece along the preset path for grinding. During this process, the frequency conversion motor adjusts the speed and torque of the grinding head in real time according to the load or curvature change.

[0024] Specifically, the spraying execution unit in this embodiment includes a spray gun robotic arm and a spray gun assembly. The spray gun robotic arm is connected to a conversion component, and the spray gun assembly is located at the end of the spray gun robotic arm. The spray gun assembly includes a spray gun and a wrench control component. The spray gun inlet is connected to a material box through a material pipe, and the air inlet is connected to an air pump through an air supply pipe. The material box contains water-based or oil-based paint. The output end of the wrench control component is connected to the wrench of the spray gun to control the start and stop of the spray gun. The spraying process is as follows: the control unit controls the air pump to supply air and controls the spray gun robotic arm, the wrench control component, and the transport robotic arm so that the spray gun sprays the workpiece surface according to a preset path, preset angle, preset atomization pressure, and travel speed.

[0025] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An intelligent grinding and spraying system, characterized in that, include: The identification module includes multiple sensors for collecting physical information about the workpiece surface. The database module includes a data processing unit, a defect analysis unit, and a control unit. The data processing unit is connected to the identification module and is used to receive physical information and construct a three-dimensional model of the workpiece surface. The defect analysis unit has a preset standard database and combines it with the three-dimensional model to identify and analyze the defect types and locations on the workpiece surface and generate repair paths for the defects. The control unit generates and outputs control signals based on the repair paths or external feedback signals. A multi-process execution module is connected to a database module. The multi-process execution module includes a conversion component and a shaping execution unit, a puttying execution unit, a sanding execution unit, and a spraying execution unit installed on the conversion component. The conversion component switches to the corresponding execution unit under the control of the control unit, and the corresponding execution unit performs the corresponding process under the control of the control unit. The monitoring module, which is set up in relation to the multi-process execution module, is used to monitor the process completed by each execution unit in real time, including the shaping execution unit, the puttying execution unit, the sanding execution unit, and the spraying execution unit, and to feed the data generated by the monitoring back to the control unit to form a closed-loop control.

2. The intelligent grinding and spraying system according to claim 1, characterized in that: It also includes a workpiece transport module, which includes a transport robotic arm and a clamp located at the end of the transport robotic arm. The clamp is used to clamp the workpiece, and the transport robotic arm is used to move the clamped workpiece from the identification module to the multi-process execution module and cooperate with the multi-process execution module under the control of the control unit.

3. The intelligent grinding and spraying system according to claim 1 or 2, characterized in that: The sensors include a 3D laser scanner and a high-precision camera.

4. The intelligent grinding and spraying system according to claim 1 or 2, characterized in that: The shaping execution unit includes a shaping servo motor and a mechanical straightening head. The fixed end of the shaping servo motor is connected to the conversion component, and the mechanical straightening head is connected to the output end of the shaping servo motor and is driven by the shaping servo motor to apply force to the deformation area of ​​the workpiece.

5. The intelligent grinding and spraying system according to claim 1 or 2, characterized in that: The putty application unit includes a scraper, an adjustment drive, and an extrusion assembly. One end of the scraper is connected to a conversion component. Both ends of the adjustment drive are connected to the scraper and the conversion component respectively to adjust the angle between the scraper and the conversion component. The extrusion assembly is adjacent to the scraper and includes a material tube, an extrusion nozzle, an extrusion rod, and an extrusion drive. The material tube is connected to the conversion component and one end communicates with the extrusion nozzle. One end of the extrusion rod is located inside the material tube, and the other end is connected to the output end of the extrusion drive. The extrusion drive is used to extrude the repair material in the material tube to the extrusion nozzle.

6. The intelligent grinding and spraying system according to claim 1 or 2, characterized in that: The grinding execution unit includes a multi-axis robotic arm, a frequency conversion grinding component, and a dust recovery component. One end of the multi-axis robotic arm is connected to a conversion component. The frequency conversion grinding component is located at the end of the multi-axis robotic arm and includes a frequency conversion motor and a grinding head. The grinding head is connected to the output end of the frequency conversion motor. The dust recovery component corresponds to the frequency conversion grinding component and is located at the end of the multi-axis robotic arm. The dust recovery component includes a cover, an air pump, and a dust collection box. The cover at least partially covers the grinding head. The air pump is connected to the cover through an air pipe. The dust collection box is located between the cover and the air pump to separate and recover dust.

7. The intelligent grinding and spraying system according to claim 6, characterized in that: The multi-axis robotic arm is a six-axis robotic arm, the grinding head is a grinding wheel, and the cover is connected to the end of the multi-axis robotic arm through a flexible bracket.

8. The intelligent grinding and spraying system according to claim 1 or 2, characterized in that: The spraying execution unit includes a spray gun robotic arm and a spray gun assembly. The spray gun robotic arm is connected to a conversion component. The spray gun assembly is located at the end of the spray gun robotic arm. The spray gun assembly includes a spray gun and a wrench control component. The spray gun inlet is connected to a material box through a material pipe, and the air inlet is connected to an air pump through an air supply pipe. The output end of the wrench control component is connected to the wrench of the spray gun to control the start and stop of the spray gun.

9. The intelligent grinding and spraying system according to claim 8, characterized in that: The material bin contains water-based or oil-based paint.

10. An intelligent grinding and spraying system according to claim 1 or 2, characterized in that: The monitoring module includes a surface vision sensor.

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