Automatic monitoring system for paint spraying film thickness of car lamp coating line

Abstract

The automatic monitoring system for the paint spraying film thickness of the car lamp coating line is provided with a product and an automatic online film thickness monitoring device, the automatic online film thickness monitoring device comprises a paint supply system, and the paint supply system comprises a paint bucket, a pump, a paint filter, a pressure regulating valve, a spray gun and a paint supply pipeline. The automatic online film thickness monitoring equipment further comprises a flow detection system and a control system, the flow detection system comprises a flow meter and a PLC control center, the flow meter is additionally arranged between the pressure regulating valve and the spray gun, and the control system receives detection data sent to the PLC control center by the flow meter in real time. Paint in the paint bucket is conveyed to the paint filter to be filtered under the pressurization effect of the pump, the filtered paint is sequentially subjected to pressure regulation of the pressure regulating valve and flow monitoring of the flow meter, and then quantitative paint is sprayed out of the spray gun and evenly sprayed on the surface of a product to form a paint film. The system realizes all-weather real-time on-line monitoring of the paint spraying film thickness of the automobile lamp coating line, avoids product quality defects, and reduces the production and operation cost.

Description

Technical Field

[0001] The utility model relates to the technical field of automatic monitoring of the thickness of the paint film of a vehicle lamp coating line, in particular to an automatic monitoring system for the thickness of the paint film of a vehicle lamp coating line. Background Art

[0002] Since the film thickness of products on existing headlight painting lines is manually inspected (once per shift), during non-inspection time, when the paint supply system suddenly malfunctions, the film thickness of the product will change, resulting in appearance quality defects. Specifically, the existing headlight painting line paint film thickness inspection technology generally includes three parts: the paint supply system, the product, and a handheld film thickness tester. Among them, the paint supply system can be designed and installed by general equipment suppliers, and the handheld film thickness tester is a common component on the market. In order to ensure that the film thickness of the product meets the quality requirements, the current operating method is to use a handheld film thickness tester to measure the paint thickness of the product after painting each shift. If the film thickness is between 8 and 15um, it meets the process requirements; if the film thickness is less than 8um or greater than 15um, it is considered unqualified, and there is a hidden danger in product quality. The defect of this technical solution is that when the amount of paint dropped on each product by the paint supply system changes during non-inspection time, it will not be discovered in time, resulting in batch defects, product quality risks, and increased production costs. Utility Model Content

[0003] The utility model aims to solve at least one of the technical problems existing in the prior art.

[0004] To this end, the utility model proposes an automatic monitoring system for the paint film thickness of a headlight coating line, which realizes all-weather real-time online monitoring of the paint film thickness of the headlight coating line, avoids product quality defects, and reduces production and operation costs.

[0005] According to the embodiment of the utility model, the automatic monitoring system for the film thickness of the paint spraying line of the headlight coating line has a product and an automatic online film thickness monitoring device, the automatic online film thickness monitoring device includes a paint supply system for outputting paint, the paint supply system includes a paint bucket, a pump, a paint filter, a pressure regulating valve, a spray gun and a paint supply pipeline, the paint bucket, pump, paint filter, pressure regulating valve and spray gun are connected in sequence by the paint supply pipeline, the automatic online film thickness monitoring device also includes a flow detection system for detecting the amount of paint sprayed on a single product and a control system for monitoring paint usage data and warning of abnormal paint usage, the flow detection system includes a flow meter and a PLC control center, the flow meter is installed between the pressure regulating valve and the spray gun, the control system receives the detection data sent by the flow meter to the PLC control center in real time, the paint in the paint bucket is transported to the paint filter for filtration by the boosting action of the pump, the filtered paint is pressure-regulated by the pressure regulating valve and flow monitored by the flow meter in turn, and then a certain amount of paint is spit out by the spray gun and evenly sprayed on the surface of the product to form a paint film.

[0006] The utility model discloses the beneficial effect is, using automatic on -line film thickness monitoring equipment instead of handheld film thickness tester, and through the control system automatic reading data, join alarm value logic operation ability, finally present on the display screen, realize automatic detection, automatic early warning, intuitive display etc.

[0007] According to an embodiment of the utility model, digital display screen is arranged on the control system to display the real -time detection data of flowmeter.

[0008] According to an embodiment of the utility model, the pump is pneumatic diaphragm pump.

[0009] According to an embodiment of the utility model, the flowmeter is ultrasonic flowmeter.

[0010] According to an embodiment of the utility model, audible -visual alarm is arranged on the control system.

[0011] According to an embodiment of the utility model, the product is arranged below the spray gun.

[0012] According to an embodiment of the utility model, the paint bucket, pump and paint filter are arranged in the paint mixing room.

[0013] According to an embodiment of the utility model, the pressure regulating valve, spray gun and flowmeter are arranged in the paint spraying room.

[0014] According to an embodiment of the utility model, the distance between the spray gun and the product is 15-20cm.

[0015] According to an embodiment of the utility model, the paint supply pipeline is stainless steel pipeline.

[0016] Other features and advantages of the utility model will be set forth in the following description, and some are apparent from the description, or are understood from the practice of the utility model. The purpose and other advantages of the utility model are realized and obtained from the structure specially pointed out in the description and drawings.

[0017] In order to make the above -mentioned purpose, feature and advantage of the utility model more obvious and easy to understand, the following preferred embodiment is specifically shown, and the detailed description is as follows by the accompanying drawings. DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments recorded in this application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0019] Figure 1 It is a schematic diagram of the structure of the utility model;

[0020] Figure 2 It is a flow monitoring alarm logic operation diagram in the key quality control system.

[0021] The labels in the figure are: 1. Product; 2. Paint bucket; 3. Pump; 4. Paint filter; 5. Pressure regulating valve; 6. Spray gun; 7. Flow meter; 8. Control system. DETAILED DESCRIPTION

[0022] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0023] In the description of the present invention, it should be understood that the terms "one side", "the other side", "both sides", "between", "middle", "upper end", "lower end", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as a limitation on the present invention.

[0024] In the description of this utility model, it should be noted that, unless otherwise expressly specified or limited, the terms "disposed" and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections, and may be directly connected or indirectly connected through an intermediary. Those skilled in the art will understand the specific meanings of the above terms in this utility model based on the specific circumstances.

[0025] The following describes in detail the automatic monitoring system for the paint film thickness of a vehicle lamp coating line according to an embodiment of the present invention with reference to the accompanying drawings.

[0026] The utility model discloses an automatic monitoring system for the film thickness of paint spraying on a headlight coating line, comprising a product 1 and an automatic online film thickness monitoring device, the automatic online film thickness monitoring device comprising a paint supply system for outputting paint, the paint supply system comprising a paint bucket 2, a pump 3, a paint filter 4, a pressure regulating valve 5, a spray gun 6 and a paint supply pipeline, the paint bucket 2, the pump 3, the paint filter 4, the pressure regulating valve 5 and the spray gun 6 being sequentially connected by the paint supply pipeline, the automatic online film thickness monitoring device further comprising a flow detection system for detecting the amount of paint sprayed on a single product 1 and a control system 8 for monitoring paint usage data and providing an early warning for abnormal paint usage, the flow detection system comprising a flow meter 7 and a PLC control center, the flow meter 7 being installed between the pressure regulating valve 5 and the spray gun 6, the control system 8 receiving detection data sent by the flow meter 7 to the PLC control center in real time, the paint in the paint bucket 2 being transported to the paint filter 4 for filtration by the boosting action of the pump 3, the filtered paint being pressure regulated by the pressure regulating valve 5 and flow monitored by the flow meter 7 in turn, and then a fixed amount of paint being spitted out by the spray gun 7 and evenly sprayed on the surface of the product 1 to form a paint film. Specifically, the paint supply system is used to output paint at a stable pressure and flow rate. The flow detection system is used to monitor the amount of paint sprayed on individual products within the paint supply system. Control system 8 is a METSYS automatic online control system. This system reads paint usage data monitored by the PLC control center and incorporates alarm logic. This system displays paint usage data in real time on the digital display screen and provides early warnings for abnormal paint usage.

[0027] Wherein, the amount of paint determines the thickness of the paint film. The control system 8 is provided with a digital display screen to display the real-time detection data of the flow meter 7. The control system 8 is provided with an audible and visual alarm.

[0028] Preferably, the product 1 is placed directly below the spray gun 6. The spray gun 6 is carried by a robot and sprayed on the product 1. The product 1 is placed directly below the robot / spray gun 6. This has the following advantages: 1) It is convenient for robot motion programming and reduces the robot's motion limit positions; 2) It increases the structural versatility of the product 1. Different forms of the product 1 will cause programming difficulties. With this layout, all products 1 on the market can be sprayed by the robot program.

[0029] Specifically, the paint bucket 2 and the pump 3 are connected by a first paint supply pipeline, the pump 3 and the paint filter 4 are connected by a second paint supply pipeline, the paint filter 4 and the pressure regulating valve 5 are connected by a third paint supply pipeline, and the pressure regulating valve 5 and the spray gun 6 are connected by a fourth paint supply pipeline. A flow meter 7 is installed on the fourth paint supply pipeline.

[0030] Preferably, the paint bucket 2, the pump 3 and the paint filter 4 are in the paint mixing room. The pressure regulating valve 5, the spray gun 6 and the flow meter 7 are in the paint spraying room. Specifically, the paint bucket 2, the pump 3 and the paint filter 4 are connected by 304 stainless steel pipelines and installed in the paint mixing room; the pressure regulating valve 5, the spray gun 6 and the flow meter 7 are connected by 304 stainless steel pipelines and installed in the paint spraying room. The pressure regulating valve 5, the spray gun 6 and the flow meter 7 are devices for adjusting and monitoring the amount of paint, and the closer to the product 1, the higher the control accuracy of the spraying amount. The paint bucket 2, the pump 3 and the paint filter 4 are large in size, and if they are placed in the paint spraying room, the robot carrying the spray gun 6 will not be able to perform the paint spraying action and will pose a collision safety hazard, so they are placed outside the paint spraying room and connected by 304 stainless steel pipelines to use the paint bucket 2, the pump 3, the paint filter 4, the pressure regulating valve 5, the spray gun 6 and the flow meter 7.

[0031] Preferably, the distance between the spray gun 6 and the product 1 is 15-20 cm, which has the advantage that the effective spraying distance of the spray gun 6 is 15-20 cm, meeting the capacity requirements of the spray gun 6.

[0032] It should be noted that the PLC control center includes a PLC control center body, an analog output module and an analog input module.

[0033] Among them, the paint bucket 2, the pump 3, the paint filter 4, the pressure regulating valve 5, the spray gun 6, the paint supply pipeline, the flow meter 7, the PLC control center, the control system 8, the analog output module and the analog input module are general parts on the market, and they are standard parts that can be directly purchased on the market.

[0034] Specifically,

[0035] The PLC control center body adopts the Mitsubishi brand FX5U-80MR / ES.

[0036] The control system 8 adopts the Emerson METSYS.

[0037] The analog output module adopts the Mitsubishi brand FX5-4DA.

[0038] The analog input module adopts the Mitsubishi brand FX5-4AD.

[0039] The paint bucket 2 is used for storing paint, and the paint bucket 2 is made of 304 stainless steel, which has the advantages of corrosion resistance and no pollution to paint for a long time.

[0040] The pump 3 is used for pressurizing and conveying paint, and the pump 3 is a pneumatic diaphragm pump. Specifically, the pump 3 adopts a Japanese imported Solid Riken pneumatic diaphragm pump, which has the advantages of corrosion resistance, stable working pressure and pressure accuracy ±0.1 bar (bar, pressure unit).

[0041] The paint filter 4 is used to filter impurities in the paint. The paint filter 4 consists of a filter cartridge and a filter element. The filter cartridge is made of 304 stainless steel and the filter element is made of PP. Its advantages are: corrosion resistance and filtration accuracy of 1um.

[0042] The pressure regulating valve 5 is used to adjust the gas pressure to ensure stability and quality during the painting process. The pressure regulating valve 5 is made of 304 stainless steel, which has the advantages of corrosion resistance, stable working pressure, and pressure accuracy of ±0.1 bar (bar, pressure unit).

[0043] The spray gun 6 is used to spray the paint evenly on the surface of the product 1. The spray gun 6 adopts the Japanese Iwata automatic spray gun, model GFA-200-084P, and the diameter is 0.8mm. Its advantages are: service life of more than 10 years, spare parts replacement cycle of more than 1 year, and paint spraying accuracy of ±1mL.

[0044] Flowmeter 7 is used to measure the flow rate of paint in the paint supply line. It is an ultrasonic flowmeter, specifically a KEYENCE PX-D8 flowmeter from Japan. Its flow rate unit is mL and it boasts high accuracy (≥ 0.5%). Flowmeter 7 operates on the principle of ultrasonic detection. By installing flowmeter 7 on the paint supply line of the paint supply system, it monitors the amount of paint used by each product during spraying and transmits the data to the control system for display, storage, and early warning.

[0045] The paint supply pipeline is made of 304 stainless steel, which has the advantages of corrosion resistance and long-term use without contaminating the paint. The diameter of the paint supply pipeline is Φ10mm, which has the advantages of ensuring that the paint supply flow and pressure meet the product use requirements.

[0046] The material of the headlight painting line spray paint product 1 is polycarbonate, referred to as PC. Since PC material has poor scratch resistance and UV resistance, it is necessary to spray a layer of UV-resistant and high-hardness paint to make up for the defects of the material itself.

[0047] See Figure 2 (Flow meter alarm), in the figure, D53 represents the flow value; 5 represents the control system reading value; X represents the reading value; Y represents the constant value; DF represents the program instruction.

[0048] The control system 8 receives the detection data from the flow meter 7 in real time and displays the real-time data on the control system's digital display screen. Logical operations are added to the control system. When the received data is greater than or less than the quantitative value ±2 (unit: mL), the control system automatically alarms and notifies the staff that the flow rate (film thickness) exceeds the standard. The principle of the logical operation is:

[0049] The first step is to read the flow meter current value through the PLC and add it into the calculation formula, as follows:

[0050] 4~20mA is the output range of the flow meter. When it works normally, the output value will vary within this range.

[0051] The calculation formula for 4-20mA analog quantity is usually based on a linear relationship. The calculation formula is:

[0052]

[0053] The meanings of the symbols in formula (1) are:

[0054] O v Indicates the conversion result, which is the paint output of a single product;

[0055] O sh Indicates the upper limit of the range, which is the constant value 100mL set by the PLC control center, and its value corresponds to the upper limit of the flow meter range 20mA;

[0056] O sl Indicates the lower limit of the range, which is the constant value 0mL set by the PLC control center, and its value corresponds to the lower limit of the flow meter range 4mA;

[0057] I v Represents the conversion object, which is the value collected by the analog module; the analog module is installed in the PLC control center.

[0058] I sh Indicates the upper limit of the signal, that is, the upper limit of the flow meter range is 20mA;

[0059] I sl Indicates the signal lower limit, which is the flow meter range lower limit 4mA.

[0060] The paint output of a single product is calculated and this value is stored in the flow PLC data memory D. The flow PLC data memory D is the data memory in the PLC control center.

[0061] The second step is the key quality control system. Communication (industrial communication protocol modbus tcp) reads the flow count value in the flow PLC data memory D and compares it with the data 8 (alarm constant value) (unit: mL). When the actual value (for example, the actual value is 5) is less than this value 8, it means that the paint output is abnormal, and an alarm is output to prompt the staff to check.

[0062] The present invention's automatic monitoring system for the film thickness of paint spraying on a headlight coating line uses an automatic online film thickness monitoring device instead of a handheld film thickness tester. The system automatically reads data through a control system, adds alarm value logic operations, and ultimately presents the data on a display screen, achieving automatic detection, automatic warning, and intuitive display capabilities. It can automatically detect in real time online. When the film thickness (flow rate) does not meet the requirements, it automatically issues an alarm and saves flow records to prevent quality risks, ensure the appearance quality of the product spraying, and effectively reduce production and operating costs. That is, the automatic monitoring system for the film thickness of paint spraying on a headlight coating line can automatically monitor the film thickness (flow rate) of a single product in the paint supply system, and can automatically store and alarm, preventing key process parameters from getting out of control and ensuring product quality is under control.

[0063] The above is only a preferred specific implementation method of the present invention, but the protection scope of the present invention is not limited to this. Any technician familiar with the technical field within the technical scope disclosed by the present invention can make equivalent replacements or changes based on the technical solution and utility model concept of the present invention, which should be covered by the protection scope of the present invention.

Claims

1. An automatic monitoring system for the paint film thickness of a headlight coating line, characterized by: With product (1) and automatic online film thickness monitoring equipment, The automatic online film thickness monitoring device comprises a paint supply system for outputting paint, wherein the paint supply system comprises a paint bucket (2), a pump (3), a paint filter (4), a pressure regulating valve (5), a spray gun (6) and a paint supply pipeline, wherein the paint bucket (2), the pump (3), the paint filter (4), the pressure regulating valve (5) and the spray gun (6) are sequentially connected by the paint supply pipeline. The automatic online film thickness monitoring device also includes a flow detection system for detecting the amount of paint sprayed on a single product (1) and a control system (8) for monitoring paint usage data and providing an early warning for abnormal paint usage. The flow detection system includes a flow meter (7) and a PLC control center. The flow meter (7) is installed between the pressure regulating valve (5) and the spray gun (6). The control system (8) receives the detection data sent by the flow meter (7) to the PLC control center in real time. The paint in the paint bucket (2) is transported to the paint filter (4) for filtration through the pressurization effect of the pump (3). The filtered paint is sequentially pressure-regulated by the pressure regulating valve (5) and flow-rate monitored by the flow meter (7). Then, the spray gun (7) spits out a fixed amount of paint and evenly sprays it on the surface of the product (1) to form a paint film.

2. The automatic monitoring system for paint film thickness of a headlight coating line according to claim 1 is characterized by: The control system (8) is provided with a digital display screen for displaying the real-time detection data of the flow meter (7).

3. The automatic monitoring system for paint film thickness of a headlight coating line according to claim 1 is characterized by: The pump (3) is a pneumatic diaphragm pump.

4. The automatic monitoring system for paint film thickness of a vehicle lamp coating line according to claim 1 is characterized by: The flow meter (7) is an ultrasonic flow meter.

5. The automatic monitoring system for paint film thickness of a vehicle lamp coating line according to claim 1 is characterized by: The control system (8) is provided with an audible and visual alarm.

6. The automatic monitoring system for paint film thickness of a vehicle lamp coating line according to claim 1 is characterized by: The product (1) is placed directly below the spray gun (6).

7. The automatic monitoring system for paint film thickness of a vehicle lamp coating line according to claim 1 is characterized by: The paint bucket (2), pump (3) and paint filter (4) are located in a paint mixing room.

8. The automatic monitoring system for paint film thickness of a vehicle lamp coating line according to claim 1 is characterized by: The pressure regulating valve (5), spray gun (6) and flow meter (7) are located in the paint spraying room.

9. The automatic monitoring system for paint film thickness of a vehicle lamp coating line according to claim 1 is characterized by: The distance between the spray gun (6) and the product (1) is 15 to 20 cm.

10. The automatic monitoring system for paint film thickness of a vehicle lamp coating line according to claim 1 is characterized by: The paint supply pipeline is a stainless steel pipeline.

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