System, procedure

Abstract

The present invention relates to a system (100), in particular a processing system (100), comprising: at least one processing robot with at least one work space (7) for receiving at least one component (6); and at least a plurality of tool units (3), which comprise at least one processing unit (3a), such as a coating unit (3aa); as well as at least one optical detection unit (3b) and / or an analysis unit (3c); and at least one control unit (4) at least for controlling the movement of the processing robot (1). At least one tool change receiving unit (2) with at least one first adapter unit (2a) and at least one second adapter unit (2b) that can be received on the first adapter unit (2a) is included. The first adapter unit (2a) is received on the processing robot (1), and a second adapter unit (2b) is received on each of the tool units (3).The invention further relates to a method for machining a component (6) with such a system (100).

Description

[0001] The present invention relates to a system, in particular a processing system, such as a coating system, comprising at least one processing robot with at least one processing unit, such as a coating unit. Furthermore, the present invention relates to a method.

[0002] Various types of processing systems have become known from the state of the art.

[0003] For example, fully automated painting systems have become known, into which the components to be coated can be introduced and processed fully automatically. The painting systems are pre-programmed for specific components. The components are optically recognized at the beginning of the coating system, for example by a camera. By comparing the camera images with a database, the component can be identified and an appropriate processing program can be loaded. The component is processed and, in particular, painted according to the processing program. Finally, the processing result can be analyzed and evaluated by an analysis unit. For this purpose, samples are usually taken from a painting system and then analyzed manually or with robot support. Such a system is only suitable for products that are manufactured at least in series production.

[0004] For special components that, for example, have particularly large dimensions or are very heavy and are only produced in small quantities, the financial outlay for an automated processing system, such as a paint line, has not yet been worthwhile, at least not in an assembled state. Furthermore, the work areas of existing coating systems may not be sufficient for comprehensive automated processing. In these cases, manual processing is the only option. This leads to particularly high costs and long processing times, making processing, especially coating, of such special components particularly expensive.

[0005] It is therefore the object of the present invention to provide a system that enables at least more economical processing of special components. Furthermore, the object of the present invention is to provide a method that enables at least more economical processing of special components.

[0006] This object is achieved by a system having the features of claim 1 and a method having the features of claim 10. Preferred developments are the subject of the subclaims. Further features and properties emerge from the general description and from the description of the exemplary embodiment.

[0007] The system according to the invention, preferably a processing system and particularly preferably a painting system, comprises: - at least one processing robot; and - at least one plurality of tool units, which comprise at least one processing unit, such as a coating unit; and at least one optical detection unit and / or one analysis unit; and - at least one control unit for controlling at least the movement of the processing robot.

[0008] At least one tool changer receiving unit is included, comprising at least one first adapter unit and at least one second adapter unit that can be received on the first adapter unit. The first adapter unit is received on the processing robot. A second adapter unit is received on each of the tool units. In particular, this allows different tool units to be received on the processing robot.

[0009] The invention has many advantages. A significant advantage of the invention is that even special components can be processed automatically using the system. At the same time, the system enables at least optical recording and / or analysis of the processing result by changing the tool unit. Transport through individual downstream stations of a coating system is advantageously not necessary, so that even special components with particularly large dimensions and / or high weight can be processed automatically. The processing robot enables a particularly high degree of flexibility, even in the recording and / or analysis and evaluation of complex component geometries, e.g., those with undercuts, and also for components with particularly large dimensions.

[0010] Preferably, at least one database is provided, which is connected to the control unit. Operation programs for controlling the processing robot can be stored in the database in a retrievable manner.

[0011] In particular, the tool units can be accommodated in a magazine. The magazine can preferably be sealed from the environment in such a way that the tool units, in particular the optical detection unit, are protected from contamination, especially from spray mist from a coating process.

[0012] In particular, the processing robot is designed as an articulated-arm robot, for example, with six or more axes of motion, as a SCARA robot, or as a delta robot. Preferably, at least a plurality of processing robots are included.

[0013] The detection unit preferably comprises at least one detection system, wherein the detection system is designed in particular as a camera, 3D camera, or laser scanner. Advantageously, the detection system enables detection of a surface of the component by the detection unit for the purpose of creating a surface model and planning a machining process or inspecting a coating result. Advantageously, an optical detection unit can comprise a plurality of different detection systems, so that a detailed measurement of the surface or an assessment of the surface quality after the machining process is also possible. In particular, the processing robot can take at least one multiple recording of at least part of a surface of a component.

[0014] Particularly preferably, the processing unit comprises at least one processing system such as a print head, a coating nozzle, a high-speed rotary atomizer, a compressed air nozzle, a jet nozzle for a cleaning medium, or the like. Advantageously, the processing unit also enables cleaning of the component prior to coating. Furthermore, information such as a component number or the like can be printed directly onto the component. A processing unit can preferably comprise a plurality of processing systems.

[0015] In particular, the analysis unit comprises at least one analysis system for analyzing and evaluating a processing result of at least one processing operation. Preferably, the analysis and evaluation of a processing result can be carried out based on the reflection properties of light rays through the surface, in particular the painted surface. Automated analysis and evaluation of a processing result is particularly preferably possible.

[0016] In particular, the analysis unit is designed according to DE 10 2017 107 115 A1 and / or according to DE 10 2022 125 197.7, which are hereby incorporated into the present disclosure.

[0017] In particular, the tool change unit is designed to be fully automatic. This advantageously eliminates the need for human intervention to switch between component detection and component processing. A fully automatic changeover is advantageously possible, allowing the changeover to be carried out autonomously and controlled by the control unit. In particular, the tool change unit is designed as a fully automatic quick-coupling unit.

[0018] The machining robot preferably has at least two tool change mounting units. This preferably accommodates a plurality of machining units or detection units. This allows machining to be performed even more precisely. Furthermore, a combined mounting of an optical detection unit and a machining unit can also be performed. This allows, for example, automatic analysis and evaluation of the machining result directly after machining.

[0019] The system, and in particular at least the tool changer unit and preferably also the tool units, are preferably designed for use in potentially explosive atmospheres. This advantageously allows the system to be used, for example, in dense spray mist from solvent-based paints. In particular, the tool units are operated purely mechanically or by an electrical storage unit. Advantageously, there are no open contacts, particularly on the adapter units, so that no sparking is possible. Alternatively, a design for non-explosive environments is also possible.

[0020] Preferably, the tool change holder unit is designed according to at least one embodiment of EP 2 919 917 B1, which is hereby fully incorporated into the present disclosure.

[0021] In particular, the control unit is at least configured and designed to control the movement of the processing robot and, in particular, also to perform a tool unit change. Advantageously, images captured by the optical detection unit or the analysis unit can be evaluated directly by the control unit.

[0022] In particular, at least one processing booth, such as a paint booth, is included. Advantageously, the paint booth allows for shielding a work area from the outside. Furthermore, a paint booth prevents dirt, such as dust, from reaching the surface of the component.

[0023] Preferably, at least one transport unit is included, which is designed in particular as a chain conveyor or as a floor conveyor. Advantageously, the component can be transported by the transport unit into a paint booth and into a workspace of the articulated arm robot. Under certain circumstances, optical detection and processing can also take place on a component that is transported through a workspace of the processing robot. Advantageously, a plurality of components can be transported simultaneously by a floor conveyor. In particular, the floor conveyor is designed as a skid-type, inverter-powered, free-type, or even an AGV conveyor. In particular, with floor conveyors, preferably at least one multi-part loading with components is possible, which can in particular be processed by different processing robots.

[0024] Further advantageous developments of the system result from the general description and the description of the embodiments.

[0025] Preferably, the system can also be part of a processing system, such as a coating system. Advantageously, the system also allows for a high degree of flexibility here.

[0026] The method according to the invention for processing at least one component, in particular by means of a system described above, comprises at least the following method steps: - Placing the component into a working area of the processing robot; - Picking up at least one tool unit designed as a machining unit by the machining robot and machining the component; and - characterized by at least one of the following process sequences: - at least receiving a tool unit designed as an optical detection unit before processing by the processing unit, in particular at least optical detection of a component surface of the component, and depositing the optical detection unit; and / or - at least depositing the optical detection unit designed as a processing unit after processing and receiving at least one analysis unit, analysis and evaluation of a processing result on the component and depositing the analysis unit.

[0027] The method according to the invention also has many advantages. A significant advantage of the method is that optical detection and processing by a processing robot are possible without the component having to be transported to another processing station. Advantageously, planning of a cleaning process and a coating process by a processing robot within a processing station, such as a paint booth, is possible. This makes it possible to process even special components with high weight and / or particularly large dimensions economically and automatically. Advantageously, optical detection and processing can therefore take place one after the other. In a method designed as a painting process, this is particularly advantageous in preventing an optical detection unit such as a camera from becoming contaminated by paint particles.The analysis of a painting result after the painting process can also be fully automated. The serial change of tool units ensures the long-term functionality of the processing system. In particular, contamination of the optical detection unit and / or the optical analysis unit is effectively prevented, preferably when the processing includes painting the component. In particular, the processing includes painting the component.

[0028] Preferably, the picking and / or setting down of the tool units is fully automated. Advantageously, no human intervention is required, especially when changing the tool units. Alternatively, manual changing is still possible, e.g., for maintenance work and the like.

[0029] Preferably, before processing by a processing unit, a part of a surface of the component is detected by at least one optical detection unit, for example to generate a surface model and to derive a processing strategy. Advantageously, at least parts of the surface of the component can be recorded by the detection unit from different positions. The recordings are then transmitted to the control unit. The control unit preferably evaluates the recordings and, in particular, generates a surface model. Preferably, the surface model is used to derive a processing strategy with at least one path plan for processing the surface of the component. Interfering contours such as transport recordings or other components in the surrounding area can be taken into account. Furthermore, at least one path plan for a control strategy can be derived based on the surface model.Subsequently, the tool unit is preferably changed from an optical detection unit to a processing unit. Preferably, the surface of the component is then machined. Particularly preferably, machining is performed by a processing unit, in particular based on the derived processing strategy. It is also possible for at least one surface model and / or one processing strategy and / or one control strategy to be predefined, so that at least one optical detection is omitted.

[0030] Subsequently, the tool unit can preferably be switched from the machining unit to the analysis unit, for example, to monitor the quality of the machining process. The control strategy derived from the surface model is preferably used for this purpose.

[0031] In particular, at least one operating program, such as a machining program of a machining strategy, a detection program for detecting the surface of the component, or even a control program of a control strategy, is optimized, particularly in production operations. Advantageously, optimization can be performed based on a specified cycle time, machining time, a quality to be achieved for a machining result, or the like. In particular, optimization is performed by the control unit using a separate software algorithm.

[0032] Preferably, the control unit controls the processing robot, processes the images as measurement data, generates the surface model, derives a processing strategy, derives a control strategy, and / or the like using a software algorithm, which is in particular based on artificial intelligence and / or comprises artificial intelligence. Advantageously, the artificial intelligence can independently derive and store rules for the efficient derivation of an operation program.

[0033] Preferably, cleaning can be carried out by a processing unit designed as a cleaning unit before an optical detection of the surface of the component or after path planning.

[0034] Preferably, a machining operation, such as a coating operation or a cleaning operation, can also be adapted and optimized during machining, particularly if two tool changer units are present on the articulated-arm robot and an optical detection unit is included as a second tool unit. Alternatively, an analysis unit can also be included, so that an evaluation of a machining result can be performed directly after machining, and this information can be used to adapt the machining process.

[0035] During optical scanning to generate a surface model, the articulated-arm robot preferably remains outside the workspace, eliminating the risk of collision with a component surface that is not yet known in detail. In particular, the processing robot's range of motion for this purpose is significantly larger than the workspace, making it possible, in particular, to scan the entire component surface with a single processing robot.

[0036] For particularly large components, the system can preferably also comprise two or more processing robots with tool changer units and tool units. In this case, in particular, a central control unit is provided, which preferably carries out movements of the articulated-arm robot and evaluates the measurement data. The system, and in particular the control unit, is preferably configured and designed to carry out the method described above.

[0037] Further features and advantages of embodiments of the invention are described below with reference to the drawings. The same reference numerals are used for identical or similar parts and for parts with identical or similar functions. They show: Fig. 1 a schematic representation of a system according to the invention for carrying out a method according to the invention with an optical detection unit and a coating unit and an analysis unit as tool units for mounting on a processing robot; Fig. 2 a schematic representation of the system with a detection unit mounted on the processing robot in a first position; Fig. 3 a schematic representation of the system with a detection unit mounted on the processing robot in a second position; Fig. 4 a schematic representation of the further embodiment of a system according to the invention with a processing unit mounted on the articulated arm robot and a further mounted optical detection unit; and Fig. 5 a schematic detailed view of a tool change unit.

[0038] It is not necessary for a system according to the invention and / or a method according to the invention to have all of the features described below. It is also possible for a system according to the invention and / or a method according to the invention to have only individual features of the exemplary embodiments described below.

[0039] Fig. 1 shows a schematic representation of a system 100 according to the invention for carrying out a method according to the invention with an optical detection unit 3b as tool unit 3 and further tool units 3, which comprise a processing unit 3a designed as a coating unit 3aa and an analysis unit 3c, for mounting on a processing robot 1 designed as an articulated arm robot 1. The tool units 3 are mounted on the articulated arm robot 1 by means of a tool change mounting unit 2. The tool change mounting unit 2 comprises a first adapter unit 2a, which is mounted on the articulated arm robot 1, and a second adapter unit 2b, on which the tool unit 3 is mounted.

[0040] The tool units 3 can be picked up and placed down fully automatically. Here, the tool units 3 are removed from a magazine 9. The tool units 3 can be placed in the magazine 9 and removed again fully automatically by the articulated arm robot 1. Furthermore, during the pick-up, a direct, fully automated coupling takes place between the first adapter unit 2a and the second adapter unit 2b of the tool changer unit 2.

[0041] A component 6 is arranged within a workspace 7. The component 6 is introduced into the workspace 7 by a transport unit 8, which is designed here as a chain conveyor 8. Alternatively, the transport unit 8 can also be designed as a floor conveyor 8. During processing, the component 6 rests in the workspace 7. The frame 8a of the chain conveyor 8 forms an interference contour 8a for the processing robot 1.

[0042] The articulated arm robot 1 enables operation on the component 6 using various tool units 3, here within a paint booth 5. First, a surface 6a of the component 6 can be captured by a capture unit 3b with a camera 3bb as the capture system 3bb. The images are then transmitted to a control unit 4 with the connected database 4a, which derives a surface model and a processing strategy with path planning for the articulated arm robot 1. After changing the tool unit 3 to a processing unit 3, which includes, for example, a processing system 3aa such as a coating unit 3aa or a cleaning unit 3aa, processing can then take place in the same paint booth 5.The processing result can be analyzed and evaluated by an analysis unit 3c with an analysis system 3cc, also using a control strategy derived from the surface model of component 6. Advantageously, the system 100 can fully automatically process and coat special components, for example, with large dimensions, which cannot be processed without fully automated processing systems. This allows special components to be processed more economically.

[0043] Fig. 2 shows a schematic representation of the system 100 with a detection unit 3b mounted on the articulated-arm robot 1 in a first position. Here, the detection unit detects the component 6 from above. During detection, the articulated-arm robot moves outside the workspace 7 in which the component 6 is arranged. This allows collisions to be avoided. Furthermore, it is particularly easy to ensure that the component 6 is completely detected and is located within a detection range 10 of the detection unit 3b.

[0044] Fig. Figure 3 shows a schematic representation of the system 100 with a detection unit 3b mounted on the articulated-arm robot 1 in a second position. Here, detection occurs from below, see Figure 1. Fig. 2. Based on the acquired images, a surface model of the surface 6a of the component 6 is generated in the control unit 4, so that a machining strategy for the fully automated machining of the component 6, as well as an analysis and evaluation of the machining, can be carried out.

[0045] Fig. Figure 4 shows a schematic representation of a further exemplary embodiment of a system 100 according to the invention with a cleaning unit 3a mounted on the articulated-arm robot 1 and a further optical detection unit 3b mounted thereon. Here, two tool change mounting units 2 are present on the articulated-arm robot 1, so that a cleaning process can be directly monitored by the analysis unit 3c with an analysis system 3cc. If necessary, rework can be performed immediately.

[0046] Fig.Figure 5 shows a schematic detailed view of the tool change unit 2. The first adapter unit 2a is mounted on the articulated-arm robot 1. The second adapter unit 2b is mounted on the first adapter unit 2a, and the tool change unit 3 is mounted on the second adapter unit 2b. The tool change unit 3 is supplied with power, e.g., paint and / or compressed air, via connecting lines. Furthermore, electrical contacts and connections are protected against sparking, enabling use in an explosion-proof environment. Reference symbols: 1 processing robot, articulated arm robot 2 tool change unit 2a first adapter unit of the tool change holder unit 2b second adapter unit of the tool change holder unit 3 Tool unit with second adapter unit 3a Processing unit, coating unit, cleaning unit 3aa processing system, print head, coating nozzle, high-speed rotary atomizer, compressed air nozzle, jet nozzle for a cleaning medium 3b Recording unit 3bb acquisition system, camera, 3D camera, laser scanner 3c Analysis unit 3cc analysis system 4 Control unit 4a Database 5 paint booth 6 Component 6a Surface of the component 7 Workspace 8 transport units 9 Magazine 10 Detection range of the detection unit 100 system, processing system QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2017 107 115 A1

[0016] DE 10 2022 125 197.7

[0016] EP 2 919 917 B1

[0020]

Claims

[1] System (100), in particular processing system (100), comprising: - at least one processing robot (1) with at least one working space (7) for receiving at least one component (6); and - at least one plurality of tool units (3), which comprise at least one processing unit (3a), such as a coating unit (3aa); and at least one optical detection unit (3b) and / or one analysis unit (3c); and - at least one control unit (4) for controlling at least the movement of the processing robot (1); characterized by that at least one tool change receiving unit (2) is comprised with at least one first adapter unit (2a) and at least one second adapter unit (2b) which can be received on the first adapter unit (2a), wherein the first adapter unit (2a) is received on the processing robot (1), and wherein a second adapter unit (2b) is received on each of the tool units (3). [2] System (100) according to claim 1, wherein the optical detection unit (3b) comprises at least one detection system (3bb), such as a camera (3bb), a 3D camera (3bb), a laser scanner (3bb) or the like. [3] System (100) according to one of the preceding claims, wherein the processing unit (3a) comprises at least one processing system (3aa), such as a print head (3aa), a coating nozzle (3aa), a high-speed rotary atomizer (3aa), a jet nozzle for a cleaning medium (3aa) or a compressed air nozzle (3aa). [4] System (100) according to one of the preceding claims, wherein the analysis unit (3c) comprises at least one analysis system (3cc) for analyzing and evaluating a processing result of a processing, which uses at least reflection properties of a processed surface (6a) of the component (6). [5] System (100) according to one of the preceding claims, wherein the tool change holder unit (2) is designed to be changeable at least semi-automatically or fully automatically. [6] System (100) according to one of the preceding claims, wherein the machining robot (1) has at least two tool change holder units (2). [7] System (100) according to one of the preceding claims, wherein at least the processing robot (1) and the tool change unit (2) and the tool units (3) are designed for use in a potentially explosive atmosphere. [8] System (100) according to one of the preceding claims, comprising at least one painting booth (5). [9] System (100) according to one of the preceding claims, comprising at least one transport unit (8), which is designed in particular as a chain conveyor (8) or as a floor conveyor (8). [10] Method for processing at least one component (6) by means of at least one system (100) according to one of the preceding claims, comprising at least the following method steps: - introducing the component (6) into the working space (7); and - mounting at least one processing unit (3a) on the processing robot (1) and processing the component (6) using a processing strategy; and - comprising at least one of the following process sequences: - at least picking up and placing down an optical detection unit before processing; and / or - at least storing the processing unit after processing and picking up at least one analysis unit. [11] Method according to the preceding claim, wherein picking up and depositing of the tool units (3) is fully automated. [12] Method according to the preceding claim, wherein the detection of the component surface (6a) by at least the optical detection unit (3b) is carried out by a plurality of recordings of at least the parts of the surface (6a) of the component (6) to be machined, and wherein the detected measurement data is used to generate at least one surface model of at least part of the surface (6a) of the component (6). [13] Method according to the preceding claim, wherein at least one processing strategy for processing by the processing unit (3a) and / or at least one control strategy for analysis and evaluation of a processing result for the analysis unit (3c) and / or a detection strategy for the detection unit (3b) is derived from the surface model. [14] Method according to one of the four preceding claims, wherein at least one operation program, such as a detection program, a processing program and / or a control program in the manufacturing operation, is optimized.

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