An automatic painting apparatus

Abstract

This utility model proposes an automatic spraying device, relating to the field of automatic spraying technology, comprising: a conveying module, a spraying module, a paint mist purification module, a safety module, a camera capture module, a control system, and a spraying chamber. The spraying module is located on one side of the conveying module, and the paint mist purification module is fixed above the conveying module. The camera capture module is fixed at the front of the conveying module. The control system is located on one side of the conveying module and is electrically connected to the other modules. The control system receives information from the camera capture module for intelligent recognition and algorithm calculation. The control system controls the operation of the spraying module and the conveying module to achieve automated spraying control. The waste gas generated by this device is treated by an electrostatic field of a water-swirl tower device and recycled within the spraying chamber. The generated water is recycled to dilute the sound-absorbing wax, resulting in no wastewater. Through machine vision-based input and path planning, a visual recognition intelligent control mechanism is implemented to meet the requirements of production environment optimization, personnel safety, product capacity expansion, and improved spraying quality.

Description

Technical Field

[0001] This utility model relates to the field of automatic spraying technology, specifically to an automatic spraying device, which is an automatic spraying device based on machine vision intelligent algorithms for product import and path planning. Background Technology

[0002] Currently, the foam sound-absorbing wax for passenger car seats is applied manually. This method requires manual spraying, and the sound-absorbing wax is dispersed into the work station and even the entire production line by high-pressure gas during the spraying process, which has a certain impact on the workshop working environment. As the product supply increases, the sound-absorbing wax spraying station is unable to meet the production rhythm, resulting in foam accumulation and easy extrusion and deformation.

[0003] There is an existing Chinese utility model patent CN209997837U, entitled "A Special Workbench for Spraying Foam Sound-Absorbing Wax for Car Seats". This utility model forms a three-dimensional water curtain inside the box, which can ensure that the release agent scattered during the spraying process enters the water curtain and dissolves in the water curtain and flows back to the water tank. However, it relies on manual labor, which affects the health of the operators. At the same time, there are problems with the incomplete treatment of waste materials and wastewater.

[0004] Therefore, there is an urgent need to invent an automatic spraying equipment to meet the production requirements of optimizing the production environment, ensuring personnel safety, expanding product capacity, and improving spraying quality. Utility Model Content

[0005] This utility model proposes an automatic spraying device to address the shortcomings of existing manual spraying of sound-absorbing wax on automotive seat foam workpieces in terms of environmental protection, health, safety, quality, and efficiency. The device is based on machine vision intelligent algorithms for product import and path planning.

[0006] To achieve the above objectives, this utility model provides the following technical solution: an automatic spraying device, comprising: a conveying module, a spraying module, a paint mist purification module, a safety module, a camera capture module, a control system, and a spraying chamber. The spraying module is located on one side of the conveying module, the paint mist purification module is fixed above the conveying module, and the camera capture module is fixed at the front of the conveying module. A control system is located on one side of the conveying module, and the control system is electrically connected to the other modules. The control system receives information from the camera capture module for intelligent identification and algorithm calculation, and controls the operation of the spraying module and the conveying module to achieve automated spraying control.

[0007] Preferably, the conveying module includes a conveyor belt, a servo motor, an encoder, and a paint mud cleaning device. The servo motor is fixedly installed at the tail of the conveyor belt. The conveyor belt is provided with a drive shaft. The servo motor drives the conveyor belt to rotate through the drive shaft. The encoder is fixedly installed on the drive shaft. The servo motor and the encoder are electrically connected to the control system. The paint mud cleaning device is fixedly connected to the bottom of the conveyor belt inlet. The paint mud cleaning device has an ultrasonic cleaning function.

[0008] Preferably, the servo motor is a three-phase permanent magnet synchronous AC servo motor, and the encoder is a 24-bit incremental optical encoder.

[0009] Preferably, the spraying module includes a spraying robot, a spray gun, and a paint supply device. The spraying robot is fixedly equipped with a spray gun, and the spray gun is connected to the paint supply device through a pipeline. The spraying robot and the spray gun are electrically connected to the control system. The spraying robot has a gear drive mechanism, and the spraying robot arm has a built-in cable.

[0010] Preferably, the safety module includes a safety gate and a light curtain, the light curtain being fixedly installed at the loading position of the workpiece to be inspected on both sides of the conveyor belt.

[0011] Preferably, the paint mist purification module includes a fan and a water vortex tower device. The fan is fixedly installed on the top of the spray booth, and the water vortex tower device is fixedly installed at the rear of the spray booth. The water vortex tower device is equipped with a super strong electrostatic field, and the fan is connected to the water vortex tower device through a pipe.

[0012] Preferably, the camera capture module includes an industrial camera and auxiliary lighting, wherein the industrial camera is fixedly installed above the conveyor belt inlet, and the auxiliary lighting is fixedly installed above the industrial camera.

[0013] Preferably, the control system includes a touch screen, a control cabinet, and an industrial computer. The touch screen is fixedly connected to one side of the control cabinet, a PLC controller is installed inside the control cabinet, and the industrial computer is located inside the control cabinet and electrically connected to the PLC controller.

[0014] Preferably, a flow sensor is fixedly installed on the pipeline connecting the spray gun and the paint supply device, and the flow sensor is electrically connected to the PLC controller.

[0015] Preferably, the industrial camera can intelligently identify the workpiece to be sprayed, the control system identifies and verifies whether the features of the workpiece to be sprayed are correct, the control system determines the actual position of the workpiece to be sprayed, the control system determines the rotation angle of the spraying robot in the horizontal and vertical directions, the control system automatically divides the rotation angle of the spraying robot into four regions: 0°–90°, 90°–180°, 180°–270°, and 270°–360°, and the control system selects the corresponding spraying trajectory according to the different regions.

[0016] Beneficial effects

[0017] This utility model provides an automatic spraying device, which has the following advantages compared with the existing technology:

[0018] This invention meets the standard requirements for spraying sound-absorbing wax on foam workpieces. The sound-absorbing wax is reasonably distributed, and there is no sound-absorbing wax adhering to other areas. Different foam states with softness and hardness before and after curing can be sprayed. No foam tearing or missing pieces will occur during the spraying process.

[0019] In this invention, the water vortex tower device is equipped with a super strong electrostatic field. The generated waste gas is treated by the electrostatic field of the water vortex tower device and directly recycled in the spraying chamber. The conveyor belt is cleaned by an ultrasonic cleaning device to remove the sound-absorbing wax remaining on the conveyor belt. The wastewater generated is recycled and diluted to dilute the sound-absorbing wax, thus no industrial wastewater is generated.

[0020] This invention utilizes a visual recognition intelligent control mechanism that incorporates machine vision and path planning to meet the requirements of optimizing the production environment, ensuring personnel safety, expanding product capacity, and improving coating quality. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0022] Figure 1 This is a front view of the assembled structure of this utility model.

[0023] Figure 2 A schematic diagram of the components for fixing the base;

[0024] Figure 3 A schematic diagram of the component structure supporting the frame;

[0025] Figure 4 This is a schematic diagram of the component structure of the claw assembly;

[0026] In the picture:

[0027] 1. Conveyor belt, 2. Servo motor, 3. Encoder, 4. Painting robot, 5. Spray gun, 6. Paint supply device, 7. Fan, 8. Water vortex tower device, 9. Paint and mud cleaning device, 10. Safety door, 11. Light curtain, 12. Industrial camera, 13. Auxiliary lighting, 14. Touch screen, 15. Control cabinet, 16. Industrial computer, 17. Workpiece to be painted. Detailed Implementation

[0028] To make the technical problems, technical solutions and beneficial effects of this utility model clearer, this utility model will be further described in detail with reference to the embodiments and accompanying drawings. It should be understood that the specific embodiments described herein are only used to explain this utility model and are not intended to limit this utility model. The technical solutions of this utility model will be described in detail below with reference to the embodiments and accompanying drawings, but the scope of protection is not limited thereto.

[0029] Please see Figure 1-4 This utility model provides a technical solution:

[0030] An automatic spraying device includes: a conveying module, a spraying module, a paint mist purification module, a safety module, a camera capture module, a control system, and a spraying chamber. The spraying module is located on one side of the conveying module, the paint mist purification module is fixed above the conveying module, the camera capture module is fixed at the front of the conveying module, and the control system is located on one side of the conveying module. The control system is electrically connected to the other modules mentioned above. The control system receives information from the camera capture module for intelligent recognition and algorithm calculation, and controls the operation of the spraying module and the conveying module to achieve automated spraying.

[0031] In some embodiments, the conveying module includes a conveyor belt 1, a servo motor 2, an encoder 3, and a paint and mud cleaning device 9. The servo motor 2 is fixedly installed at the tail of the conveyor belt 1. The conveyor belt 1 is provided with a drive shaft. The servo motor 2 drives the conveyor belt 1 to rotate through the drive shaft. The encoder 3 is fixedly installed on the drive shaft. The servo motor 2 and the encoder 3 are electrically connected to the control system. The paint and mud cleaning device 9 is fixedly connected to the bottom of the inlet of the conveyor belt 1. The spraying module includes a spraying robot 4, a spray gun 5, and a paint supply device 6. The spraying robot 4 is fixedly installed with the spray gun 5. The spray gun 5 is connected to the paint supply device 6 through a pipeline. The spraying robot 4 and the spray gun 5 are electrically connected to the control system. The spraying robot 4 has a gear drive mechanism. The arm of the spraying robot 4 has a built-in cable.

[0032] In some embodiments, the paint mist purification module includes a fan 7 and a water vortex tower device 8. The fan 7 is fixedly installed on the top of the spray booth, and the water vortex tower device 8 is fixedly installed at the rear of the spray booth. The fan 7 is connected to the water vortex tower device 8 through a pipe. The camera capture module includes an industrial camera 12 and an auxiliary lighting 13. The industrial camera 12 is fixedly installed above the inlet of the conveyor belt 1, and the auxiliary lighting 13 is fixedly installed above the industrial camera 12. The control system includes a touch screen 14, a control cabinet 15, and an industrial computer 16. The touch screen 14 is fixedly connected to one side of the control cabinet 15. A PLC controller is provided inside the control cabinet 15, and the industrial computer 16 is located inside the control cabinet 15 and is electrically connected to the PLC controller.

[0033] In some embodiments, the workpiece 17 to be coated in this application is a car seat foam workpiece.

[0034] In some embodiments, after necessary processing steps, the workpiece 17 to be coated is placed on the conveyor belt 1 with the coating surface facing upwards by the operator. The operator does not need to specifically adjust the angle of the workpiece 17 to be coated, and the workpiece 17 is automatically transported into the coating equipment by the conveyor belt 1 for coating. The operator only needs to ensure that there is sufficient clearance (>50mm) between the two workpieces in the vertical direction of the workpiece 17 to be coated. The industrial camera 12 controls the coating robot 4 to achieve automated coating through intelligent recognition and algorithm calculation, eliminating the need for additional manual labor for tasks such as placement and touch-up spraying.

[0035] In some embodiments, a 24-bit incremental optical encoder 3 is used in conjunction with a high-speed digital signal processor to control the IGBT to generate precise cable output, which drives a three-phase permanent magnet synchronous AC servo motor 2 to achieve precise positioning. The servo motor 2 has a speed of 3000 rpm.

[0036] In some embodiments, the intelligent control system of the industrial camera 12 can continuously and automatically identify various workpieces 17 to be sprayed from the conveyor belt 1, match the spraying route and flow rate of the noise-absorbing wax, and complete the automatic spraying of the noise-absorbing wax. The speed range of the conveyor belt 1 is 180mm / s-220mm / s. The intelligent control system calculates a suitable speed to match the conveyor belt 1, providing sufficient space for the identification and automatic spraying of the workpieces 17 to be sprayed.

[0037] In some embodiments, the industrial camera 12 is equipped with a superior image sensor, featuring high dynamic range, good signal-to-noise ratio, and excellent image quality. It also boasts excellent power consumption design, compatibility with machine vision standard protocols and the GenlCam standard, and utilizes machine vision recognition software to develop intelligent algorithms, thereby improving the accuracy of multi-product recognition and the fault tolerance of machine vision. Furthermore, it supports TCP / IP communication and can communicate freely with a PLC controller.

[0038] In some embodiments, the water vortex tower device 8 uses "water vortex washing" as the core washing and filtration principle to recover the noise-reducing wax paint mist generated during the spraying process, avoiding the spread of paint mist and damage to the workshop environment. Using this device to treat exhaust gas, the exhaust gas collection control wind speed is not less than 0.5m / s. After treatment by the water vortex tower device 8, at least 99% of the noise-reducing wax in the exhaust gas is removed, realizing internal circulation. In addition, the wastewater is recycled and reused for the preparation of spraying raw materials. No hazardous waste is generated or operating costs are increased during the entire process.

[0039] In some embodiments, the amount and position of the sound-absorbing wax sprayed are adjusted in real time based on the visual recognition of the type and placement of the workpiece 17 to be sprayed by the industrial camera 12, and can be displayed on the touch screen 14 of the control system. The touch screen 14 has a relevant interface and simple operation process, and technicians can adjust the appropriate spraying path and spraying flow as needed.

[0040] The control system has a flow calibration function. The operator can calibrate the flow of the spray gun 5 through the touch screen 14. During the flow calibration process, multiple spraying times can be set, and the spraying flow is automatically calculated and recorded with a system error of less than 5%.

[0041] The workpiece 17 to be coated is coated according to the specified coating surface and coating path. The control system adjusts the coating time and coating path according to the intelligent algorithm of the industrial camera 12, so that the foam will not be damaged due to non-coating reasons and affect the use of the workpiece 17 to be coated.

[0042] In some embodiments, the painting robot 4 has a gear drive mechanism for its arm and wrist. The arm cable of the painting robot 4 is built-in, and its movement stroke is 1831 mm. It has better rigidity and repeatability positioning accuracy of ±0.02 mm. The painting robot 4 and the industrial camera 12 communicate in real time for visual recognition, and online tracking and path planning enable the product to follow the painting process during production line transfer.

[0043] In some embodiments, the industrial camera 12 and the light curtain 11 are both connected to the industrial computer 16 and the PLC controller in the control cabinet 15 via communication cables and signal cables. The industrial computer 16 collects the data from the industrial camera 12 and transmits commands to the PLC controller after the recognition software uses intelligent algorithms. The PLC controller controls the speed of the conveyor belt 1 and the running posture of the spraying robot 4 to complete the automatic spraying of various workpieces 17 to be sprayed.

[0044] In some embodiments, the industrial camera 12 has the function of intelligently identifying the category of the workpiece 17 to be sprayed. The intelligent algorithm uses the unique feature points of the workpiece 17 to confirm whether the industrial camera 12 has made the correct judgment. At the same time, the feature is used to calculate the actual position of the workpiece 17 to be sprayed and the rotation angle of the spraying robot 4 in the X and Y directions. The angle is automatically divided into four regions: 0°–90°, 90°–180°, 180°–270° and 270°–360°. The corresponding spraying trajectory is selected according to the different regions. At the same time, the position and angle deviation between the teaching trajectory is automatically calibrated and taught.

[0045] In some embodiments, the visual recognition system has a correct recognition rate of 17 to be sprayed, a spraying path, and a comprehensive correct execution rate of spraying actions that is greater than 99%. During continuous spraying, the spraying robot 4 moves directly from the end point of the previous spraying of the workpiece 17 to be sprayed to the starting point of the next workpiece 17 to be sprayed and starts working immediately. When a foam break occurs in the middle, it returns to its original position. After the sound-absorbing wax is sprayed, the workpiece 17 to be sprayed leaves the automatic sound-absorbing wax spraying equipment and flows to the hanging station with the conveyor belt 1. There are no foam tears or missing pieces during the spraying process.

[0046] Working principle of this utility model:

[0047] This invention relates to an automatic spraying device for applying sound-absorbing wax to foam workpieces used in passenger car seats. A conveyor belt 1 is driven by a servo motor 2 mounted at its tail. An incremental optical encoder 3 mounted on its drive shaft records the real-time position of the workpiece 17 to be sprayed on the conveyor belt 1. A spraying robot 4 is located on the left side of the conveyor belt 1 in its direction of travel. The spraying robot 4 is equipped with a spray gun 5 for spraying the sound-absorbing wax. An industrial camera 12 and auxiliary lighting 13 are installed above the center of the conveyor belt 1 in the direction of its inlet. Light curtains 11 are installed on both sides of the conveyor belt 1 at the workpiece 17 to be sprayed, detecting the position of the workpiece to be sprayed. When workpiece 17 passes through light curtain 11, it sends a signal to industrial camera 12 for image recognition. Workpiece 17 to be painted varies in shape due to different vehicle configurations and installation positions. Furthermore, the direction and angle at which the operator places workpiece 17 on conveyor belt 1 also vary. Industrial camera 12 takes online photos, recognizes and imports the images. Through the intelligent algorithm of industrial computer 16 combined with the encoder 3 values ​​on conveyor belt 1 given by PLC controller in control cabinet 15, it calculates the walking position and shape trajectory of workpiece 17 to be painted, thereby controlling the spray gun 5 equipped by painting robot 4 to perform intelligent wax spraying.

[0048] The paint supply device 6 of this utility model is located in the batching area near the outlet of the conveyor belt 1. It is used for the preparation and supply of fluid noise-absorbing wax. At the same time, during the robot spraying process, the fan 7 installed on the top of the chamber and the water vortex tower device 8 at the rear of the chamber are used to circulate and recycle the wax mist that drifts into the air inside the chamber. Meanwhile, the paint mud cleaning device 9 installed at the bottom of the inlet of the conveyor belt 1 cleans the wax liquid remaining on the conveyor belt in a timely manner, so that the production environment meets the environmental protection requirements.

[0049] A safety door 10 is installed on the side of the spraying chamber. When a maintenance worker opens the safety door 10 to enter the chamber, a safety interlock signal will be triggered, and the control system will stop the operation of the conveyor belt 1 and the spraying robot 4 to ensure personnel safety. A touch screen 14 is installed on the side of the control cabinet 15 for human-machine interaction, setting various parameters of the control equipment, and displaying data such as the model, picture and spraying amount of each workpiece 17 to be sprayed, so as to facilitate the manager to track product production information.

[0050] The above description is a further detailed explanation of the present invention in conjunction with specific preferred embodiments. For those skilled in the art to which the present invention pertains, several simple deductions or substitutions can be made without departing from the present invention, and all such deductions or substitutions should be considered as falling within the scope of patent protection determined by the submitted claims.

Claims

1. An automatic spraying device, characterized in that: include: The system comprises a conveying module, a spraying module, a paint mist purification module, a safety module, a camera capture module, a control system, and a spraying chamber. The spraying module is located on one side of the conveying module, and the paint mist purification module is fixed above the conveying module. The camera capture module is fixed at the front of the conveying module, and the control system is located on one side of the conveying module. The control system is electrically connected to the other modules mentioned above. The control system receives information from the camera capture module, performs intelligent recognition and algorithm calculations, and controls the operation of the spraying module and the conveying module to achieve automated spraying control.

2. An automatic painting apparatus according to claim 1, characterized in that: The conveying module includes a conveyor belt, a servo motor, an encoder, and a paint mud cleaning device. The servo motor is fixedly installed at the tail of the conveyor belt. The conveyor belt is provided with a drive shaft. The servo motor drives the conveyor belt to rotate through the drive shaft. The encoder is fixedly installed on the drive shaft. The servo motor and the encoder are electrically connected to the control system. The paint mud cleaning device is fixedly connected to the bottom of the conveyor belt inlet. The paint mud cleaning device has an ultrasonic cleaning function.

3. An automatic painting apparatus according to claim 2, characterized in that: The servo motor is a three-phase permanent magnet synchronous AC servo motor, and the encoder is a 24-bit incremental optical encoder.

4. An automatic painting apparatus according to claim 2, characterized in that: The spraying module includes a spraying robot, a spray gun, and a paint supply device. The spraying robot is fixedly equipped with a spray gun, and the spray gun is connected to the paint supply device through a pipeline. The spraying robot and the spray gun are electrically connected to the control system. The spraying robot has a gear drive mechanism, and the spraying robot arm has built-in cables.

5. An automatic painting apparatus according to claim 2, characterized in that: The safety module includes a safety gate and a light curtain, which are fixedly installed on both sides of the conveyor belt at the loading positions of the workpieces to be inspected.

6. An automatic painting apparatus according to claim 1, characterized in that: The paint mist purification module includes a fan and a water vortex tower device. The fan is fixedly installed on the top of the spray booth, and the water vortex tower device is fixedly installed at the rear of the spray booth. The water vortex tower device is equipped with a super strong electrostatic field, and the fan is connected to the water vortex tower device through a pipe.

7. An automatic painting apparatus according to claim 4, characterized in that: The camera capture module includes an industrial camera and auxiliary lighting. The industrial camera is fixedly installed above the conveyor belt inlet, and the auxiliary lighting is fixedly installed above the industrial camera.

8. An automatic painting apparatus according to claim 7, characterized in that: The control system includes a touch screen, a control cabinet, and an industrial computer. The touch screen is fixedly connected to one side of the control cabinet, and a PLC controller is installed inside the control cabinet. The industrial computer is located inside the control cabinet and is electrically connected to the PLC controller.

9. An automatic painting apparatus according to claim 8, wherein A flow sensor is fixedly installed on the pipeline connecting the spray gun and the paint supply device, and the flow sensor is electrically connected to the PLC controller.

10. An automatic painting apparatus according to claim 8, characterized in that: The industrial camera can intelligently identify the workpiece to be sprayed. The control system identifies and verifies whether the features of the workpiece to be sprayed are correct. The control system determines the actual position of the workpiece to be sprayed. The control system determines the rotation angle of the spraying robot in the horizontal and vertical directions. The control system automatically divides the rotation angle of the spraying robot into four regions: 0°–90°, 90°–180°, 180°–270°, and 270°–360°. The control system selects the corresponding spraying trajectory according to the different regions.

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