Measurement reference body and method of measuring coating material thickness

Abstract

To provide a method capable of measuring a coating thickness which is precise in an area without using a measuring pin after construction of a coating material, and a measurement reference body used for the measurement method.SOLUTION: A measurement reference body 30 measures a thickness of a coating material constructed on a target surface, in which the measurement reference body has a bottom surface 31 having the same function as the coating material and being fixed to the target surface, and a height H from the bottom surface to a top part 32 is greater than a thickness of the coating material to be constructed.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a method for measuring the thickness of a covering material applied to planar portions such as the walls, floors, ceilings, and roofs of buildings. [Background technology]

[0002] Various functional layers are formed on the walls of buildings by painting, plastering, spraying, and other methods. For example, a foaming liquid containing a foaming material added to a main raw material is sprayed onto the surface to be treated, and the foaming and solidifying process is used to apply the insulation material. In order to keep the thickness of the insulation material within a specified range, the foaming material is sprayed onto the surface to be treated and foamed and solidified, and then the thickness is checked, and correction processing is required to cut off the excess in areas that are too thick and to add more in areas that are too thin. Conventionally, at the work site, after the work is performed, a needle-shaped measuring gauge is inserted into each part of the foamed and solidified insulation material to measure the thickness and to check whether correction processing is required in each part. However, the thickness of the insulation material can only be measured at discrete points where the measuring gauge is inserted, and surface quality control is not possible.

[0003] To address the above problem, Patent Document 1 describes a method for measuring the thickness of a coating material applied to a target surface, in which the three-dimensional coordinates of a reference marker installed on or near the coating material are used as reference three-dimensional coordinates, a virtual plane is calculated based on the reference three-dimensional coordinates of three or more points that are at known and the same distance from the target surface, and the thickness of the coating material is calculated based on the three-dimensional coordinates of the surface of the coating material and the virtual plane. Patent Document 2 describes a measuring pin for measuring the thickness of a thermal insulating material applied to a target surface, in which a pressing part provided on the head can be used as a reference marker a predetermined distance away from the target surface.

[0004] Patent Document 3 describes a method for applying a fire-resistant coating material, in which a thickness target made of the same components as the fire-resistant coating material is provided on the surface of the fire-resistant coating object, and the fire-resistant coating material is applied using the thickness target as a guide. This allows the application to be performed while visually checking the target thickness, which is said to reduce thickness variation. It also describes that in the painting process, image information of the unevenness of the coating surface is obtained using a 3D scanner, and it is determined that a coating film of a predetermined thickness has been formed when the unevenness of the thickness target disappears. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. WO2020 / 179336 [Patent Document 2] JP 2020-143965 A [Patent Document 3] JP 2020-125620 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, with the methods described in Patent Documents 1 and 2, when the pin is removed after measuring the thickness of the coating material, a pin hole remains in the coating material, and using multiple pins to improve the accuracy of the thickness measurement results in an increased number of holes, which is a problem.

[0007] In addition, in the method described in Patent Document 3, it is possible to determine whether a coating material of a specified thickness has been formed by focusing on the unevenness of the painted surface, but it is difficult to measure the coating thickness precisely across the surface. In particular, in the spraying method, a thickness target of the same thickness as the planned thickness of the coating material is used as a guide for the thickness of the coating material, so it is difficult to apply the thickness target without making it buried in the coating material, making it even more difficult to measure the coating thickness precisely across the surface.

[0008] The present invention has been made in consideration of the above, and aims to provide a method capable of measuring coating thickness precisely over a surface area without using measurement pins that are installed after the coating material is applied, and a measurement reference body for use in such a measurement method. [Means for solving the problem]

[0009] The measurement standard body of the present invention is a measurement standard body for measuring the thickness of a coating material applied to a target surface, which has the same function as the coating material, has a bottom surface fixed to the target surface, and has a height from the bottom surface to the top that is greater than the planned thickness of the coating material. Here, the function of the measurement standard body that is the same as the coating material means the function that is the purpose of the application of the coating material.

[0010] The coating material thickness measurement method of the present invention is a method for measuring the coating material thickness using the above-mentioned measurement reference body, and includes the steps of fixing three or more of the measurement reference bodies having the same height from the bottom surface to the top to the target surface, acquiring an application shape including a three-dimensional shape of the coating material surface and the top after the coating material is applied to the target surface to which the measurement reference bodies are fixed, setting measurement reference points on the tops of the three or more measurement reference bodies, and calculating the thickness of the coating material based on the three-dimensional shape of the coating material surface and the three-dimensional coordinates of the measurement reference points. Effect of the Invention

[0011] According to the measurement standard or coating thickness measurement method of the present invention, after the coating is applied, the absolute value and distribution of the coating thickness can be precisely measured on a surface based on the three-dimensional shape of the coating surface and the three-dimensional coordinates of the measurement standard point set at the top of the measurement standard. In addition, since the measurement standard has the same function as the coating, it is not necessary to remove the measurement standard from the coating after measuring the coating thickness, and unlike the case of using a measurement pin, there is no problem of pin holes remaining in the coating. In addition, since the thickness of the measurement standard is larger than the planned thickness of the coating, the measurement standard is not buried in the coating, and accurate thickness measurement is possible. [Brief description of the drawings]

[0012] [Figure 1] 1 is a configuration example of a measurement system used in a coating material thickness measurement method according to one embodiment. [Diagram 2] 1 is a measurement standard of one embodiment. [Diagram 3] FIG. 1 is a process flow diagram of a coating material application operation including a coating material thickness measurement method according to one embodiment. [Figure 4] 5A to 5E are diagrams for explaining the steps of a coating material thickness measurement method according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] An embodiment of the measurement standard and the coating material thickness measuring method of the present invention will be described with reference to FIGS.

[0014] In the coating thickness measurement method of this embodiment, a measurement standard body is fixed to the application target surface, and after the coating material is applied, the coating material and the measurement standard body are measured in three dimensions, and the thickness of the coating material is calculated based on the measurement standard point set at the top of the measurement standard body. In the following, a description will be given assuming that the wall surface of a building is the target surface, and the insulation material sprayed onto the target surface is the coating material, and the thickness of the insulation material is measured.

[0015] 1, a measurement system 10 used in this embodiment includes a three-dimensional measuring device 11, a control unit 14, and a display unit 17. The control unit 14 includes a storage unit 15 and a data processing unit 16. The storage unit 15 stores the construction shape and the like measured by the three-dimensional measuring device 11. The data processing unit 16 performs calculations for three-dimensional measurement and various calculations for calculating the thickness of the insulating material, and creates an image to be displayed on the display unit 17. The display unit 17 is, for example, a liquid crystal monitor that displays the image created by the data processing unit 16.

[0016] The three-dimensional measuring device 11 measures the applied shape. The applied shape includes the three-dimensional shape of the surface of the insulation material (covering material) 21 applied to the wall surface (target surface) 20, and the three-dimensional shape of the top of the measurement reference body 30 fixed to the wall surface that protrudes from the insulation material.

[0017] The type of three-dimensional measuring device 11 is not particularly limited, and devices that can be used include a LIDAR type that irradiates laser light onto the surface to be measured and calculates the three-dimensional shape of the target surface from the reflected light, a TOF type that measures distance based on the time it takes for the irradiated light to be reflected and returned, a stereo type that calculates the three-dimensional shape from images captured by two cameras using the principles of triangulation, and an active stereo type in which one of the two cameras in the stereo type is replaced with a projector that projects linear or other patterned light.

[0018] The 3D measuring device 11 is preferably of the active stereo type. This is because the stereo type has high measurement accuracy when the distance to the measurement target is short, such as when measuring indoors. Also, by projecting a pattern, stereo corresponding points can be easily found in the pattern even in a place with few distinctive features such as walls, floors, and roofs. FIG. 1 shows a 3D measuring device 11 of the active stereo type, which projects a pattern of infrared light or the like from the projection unit 13 and captures an image with the imaging unit 12.

[0019] The 3D measuring device 11 is preferably a handheld type that can perform 3D measurements while shifting the area to be measured and sequentially combine the measurement results to obtain the 3D shape of the entire target surface. For indoor construction sites that are narrow and have many obstacles, a handheld type that is easier to operate than a stationary type is more suitable.

[0020] In addition, it is preferable that the construction shape includes color information. For example, if a 3D measuring device capable of acquiring color images simultaneously with 3D coordinates is used, point cloud data with color information added can be generated. This makes it possible to identify the measurement reference body 30 in the image based on the color information.

[0021] FIG. 2 shows an example of a measurement standard body. The measurement standard body 30 has a bottom surface 31 and a top portion 32. The bottom surface 31 is fixed to the target surface 20 prior to the application of the covering material 21. The bottom surface is preferably flat. The measurement standard body 30 is used with a height H that is greater than the planned thickness of the covering material after application. This allows the top portion 32 to protrude from the insulation material even after the insulation material is applied. The top portion 32 is preferably a flat surface that is parallel to the target surface when the measurement standard body is fixed to the target surface. A measurement standard point that serves as a measurement standard during three-dimensional measurement of the applied shape is set on the top portion, and by making the top portion a flat surface parallel to the target surface, the position of the measurement standard point can be calculated with high accuracy. Preferably, the color of the top portion is different from the color of the covering material and other parts of the measurement standard body. This is to make it easier to identify by image. For example, the top surface may be colored.

[0022] The overall shape of the measurement standard body 30 can be determined taking into consideration ease of manufacture, ease of application of the covering material 21 when fixed to the target surface 20, and difficulty of falling off after application. From the viewpoint of ease of manufacture, the measurement standard body is preferably a columnar shape such as a rectangular column or a cylinder, and more preferably a rectangular parallelepiped shape including a cube. If the shape of the measurement standard body is a rectangular parallelepiped, cutting is not required and it can be manufactured only by cutting, in addition, there is no waste of material during manufacturing, and the filling efficiency during packaging and transportation is good. On the other hand, if importance is placed on not interfering with the application work, the measurement standard body is preferably a columnar shape with no corners on the side such as a cylinder, or various truncated pyramid shapes such as a truncated pyramid or a truncated cone, more preferably a truncated cone shape, and particularly preferably a truncated cone shape with no corners on the side such as a truncated cone. If the shape of the measurement standard body is a truncated cone, it is easy to apply without leaving any gaps around the measurement standard body, even when a sprayed polyurethane insulation material of a site foaming type, which is relatively difficult to apply, is used as the covering material. Furthermore, if the measurement reference body has a truncated cone shape, by fixing the larger of the two parallel planes of the truncated cone to the target surface as the base, the measurement reference body will not fall off the covering material even if its fixation to the target surface becomes loose or comes undone due to changes over time after construction.

[0023] The measurement standard body 30 has the same function as the coating material. Here, the same function refers to the function that is the purpose of applying the coating material. For example, if the coating material is a heat insulating material, the function is heat-insulating, if the coating material is a fire-resistant coating, the function is fire-resistant, if the coating material is a waterproof coating, the function is waterproof, etc. This allows the measurement standard body to be left in the coating material without being removed after the coating material is applied.

[0024] The material of the measurement standard body 30 is preferably substantially the same as that of the covering material 21. Being made of substantially the same material means that the components and structure of the measurement standard body are similar to those of the covering material, and even if the components and structure are different, the difference is within a range that does not lose the function intended by the above-mentioned construction. This allows the measurement standard body to have the same function as the covering material, and good adhesion is obtained between the measurement standard body and the covering material. For example, if the covering material is a sprayed urethane insulation material that is foamed in place, it is preferable that the measurement standard body is made of a foamed urethane material. However, even in this case, it is not necessary to cut out the measurement standard body from the insulation material foamed by spraying work, and for example, the hardness of the measurement standard body and the covering material may be different due to different foaming ratios.

[0025] The measurement standard body 30 preferably has a protective film 33 on its top 32. Since the height of the measurement standard body is greater than the thickness of the covering material, the top will not be buried in the covering material when the covering material is applied. However, when the covering material is sprayed and applied, splashes may adhere to the top, causing errors in three-dimensional measurement. By providing a protective film on the top of the measurement standard body, when the protective film is peeled off after the covering material is applied, a flat and clean top free of splashes or other unnecessary adhesions will appear. Furthermore, if a colored protective film is used as the protective film, it will be easier to find if the protective film has been left unpeeled.

[0026] Next, the method of this embodiment will be described with reference to Fig. 4 along the flow of Fig. 3. In the following, the direction in which the target surface extends is called the "surface direction", and the direction perpendicular thereto is called the "thickness direction". Also, something that is in front of the target surface when viewed from the thickness direction is simply said to be "within the surface" of the target surface. The same applies to the coating material.

[0027] In the coating thickness measurement method of this embodiment, (S1) a measurement reference body is fixed to the target surface 20, (S2) the coating material is applied, (S3) the applied shape is acquired, (S4) a measurement reference point is set at the top of the measurement reference body to calculate a virtual plane, and (S5) the coating material thickness is calculated. The application work continues, after which (S6) a coating material image is displayed, and (S7) it is determined whether correction processing is required. If it is determined that correction processing is required, (S8) the correction processing is performed, and then steps S3 and after are repeated. If it is determined that correction processing is not required, (S9) a finishing process is performed, and (S10) the required data is saved, completing the work.

[0028] (S1) The bottom surface 31 of the measurement reference body 30 is fixed to the target surface, that is, the wall surface 20 (FIG. 4A). The measurement reference body in FIG. 4A has a protective film 33 on the top 32. There are no particular limitations on the method for fixing the bottom surface 31 to the wall surface, and various known adhesives and pressure-sensitive adhesives such as acrylic, urethane, and silicone adhesives, double-sided tape having adhesive layers on both sides, etc. can be used. When the covering material is a foam-in-place type sprayed urethane insulation material, it is preferable to use an acrylic adhesive or pressure-sensitive adhesive that is heat resistant to the heat generated during construction.

[0029] The measurement reference body 30 is fixed at three or more locations that are not on a straight line within the target surface. This allows a virtual plane that passes through the measurement reference point and is parallel to the target surface when a measurement reference point is later set at the apex 32. The measurement reference body is preferably fixed at four or more locations. As will be described later, the more measurement reference bodies there are, i.e., the more measurement reference points there are, the more the measurement accuracy of the coating material thickness can be improved. In addition, the measurement reference bodies are preferably distributed over the entire surface of the target surface. This is because, as will be described later, the more the measurement accuracy of the coating material thickness can be improved.

[0030] (S2) A heat insulating material 21, which is a covering material, is applied to the target wall surface 20 (FIG. 4B). The application method is not particularly limited. For example, spray-applied rigid polyurethane foam for building insulation, as specified in JISA9526, can be applied by a spraying method. When applying the covering material by spraying, splashes 22 of the raw material may adhere to the top 32 of the measurement standard body 30. To address this problem, a protective film 33 may be attached to the top of the measurement standard body and then peeled off before obtaining the applied shape in the next step S3. The type of covering material is not particularly limited, and various layers such as a heat insulating layer, a fireproof covering layer, a fireproof covering layer, a waterproof covering layer, a moisture-proof covering layer, and a corrosion-proof covering layer may be formed, and the application of the covering material can be performed by various methods such as spraying, spraying, and coating.

[0031] (S3) The working shape C is obtained using the three-dimensional measuring device 11 (FIG. 4C). The working shape includes the three-dimensional shape of the surface of the covering material 21 and the three-dimensional shape of the top 32 of the measurement reference body 30 protruding from the covering material. If the measurement reference body has a protective film 33 on its top, the protective film is removed before obtaining the working shape. The method of expressing the three-dimensional shape is not particularly limited as long as it can be processed on a computer. For example, it may be expressed as point cloud data, which is a collection of three-dimensional coordinates of the surface, or it may be expressed as a polygon mesh or a mathematical expression or parameter expression of a plane / curved surface, or a volume data expression of the target part (voxel, etc.), or a combination of these.

[0032] (S4) A measurement reference point R is set on the top 32 of the measurement reference body 30, and a virtual plane V is calculated (FIG. 4D). If the top 32 is a plane, and the measurement reference point R is set at its center of gravity, the position of the measurement reference point can be calculated easily and accurately by image processing. At this time, if there are splashes of the coating material raw material adhering to the top 32, this will cause an error in the calculation of the position of the measurement reference point R. To solve this problem, as mentioned above, a measurement reference body with a protective film 33 on its top can be used.

[0033] If the heights H of multiple measurement reference bodies are the same, the distance from the target surface 20 to the measurement reference point R set at the top of each measurement reference body will be the same. Therefore, by connecting multiple measurement reference points, a virtual plane V parallel to the target surface can be determined. If there are three measurement reference points, the virtual plane V can be calculated. If there are four or more measurement reference points, the virtual plane V can be found with higher accuracy by fitting using the least squares method or the like.

[0034] (S5) Calculate the thickness of the coating material based on the three-dimensional shape of the surface of the insulating material 21, which is the coating material, and the three-dimensional coordinates of three or more measurement reference points R (FIG. 4E). The distance between the virtual plane V and the target surface 20 is known and is equal to the height H of the measurement reference body 30. Therefore, by calculating the distance t1 between the virtual plane V and the surface of the coating material 21 and subtracting it from H, the distance from the target surface 20 to the coating material surface, i.e., the thickness t2 of the coating material, is obtained as t2=H-t1.

[0035] In this way, the absolute value and distribution of the coating material thickness can be calculated over the entire target surface. Details of the coating material thickness calculation method are disclosed in Patent Document 1.

[0036] (S6) A coating material image is created and displayed on the display unit 17. Here, the coating material image refers to an image in which the thickness t2 of the insulating material 21, which is the coating material, can be recognized. The coating material image can be, for example, a contour diagram in which the insulating material is divided into multiple regions by color or shaded according to thickness. This makes it easy to identify areas where the thickness of the coating material is outside a predetermined range based on the required specifications.

[0037] (S7) Based on the coating material image, if there is an area where the coating material thickness does not satisfy the required specifications, it is determined that correction processing is necessary, and if there is no area, it is determined that correction processing is not necessary.

[0038] (S8) If it is determined in step S7 that correction processing is necessary, the coating material is corrected. Specifically, in areas where the coating material is too thick, the excess is cut away, and in areas where it is too thin, additional coating material is applied on top of the excess. After correction processing is performed, the application shape is acquired again (S3), a measurement reference point is set (S4), the thickness of the coating material after correction processing is calculated (S5), an image of the coating material is displayed (S6), and it is determined whether further correction processing is necessary (S7).

[0039] (S9) If it is determined in step S7 that no correction processing is required, the process proceeds to finishing processing. In finishing processing, the portion of the measurement reference body 30 that protrudes from the coating material is cut off. In addition, if necessary, processing such as applying a top coat to protect the entire surface of the coating material is performed.

[0040] (S10) Various data such as the thickness of the coating material, images of the coating material, and the construction shape are stored. Specifically, the data stored in the storage unit 15 is copied to a storage medium or copied to a server in another location via a network. By storing data such as the thickness of the coating material, it can be used for quality assurance to the client at a later date.

[0041] Among the above steps, the application of the coating layer (S2), the correction process (S8) and the finishing process (S9) may be carried out by a business operator different from the other steps constituting the coating layer thickness measurement method of this embodiment.

[0042] The present invention is not limited to the above-described embodiment, and various modifications are possible within the scope of the technical concept of the invention.

[0043] For example, the target surface is not limited to the wall surface of a building, but may be a surface portion such as a floor, roof, ceiling, rooftop, etc. Furthermore, the covering material is not limited to a thermal insulation material that is sprayed, but may be a material other than a thermal insulation material that is waterproof, fireproof, fireproof, non-combustible, flame-retardant, or a material that combines these functions. [Explanation of symbols]

[0044] 10. Measurement System 11 3D measuring device 12 Imaging unit 13 Projection section 14 Control section 15 Storage section 16 Data Processing Section 17 Display 20 Wall (target surface) 21 Insulation materials (covering materials) 22 Splashes of insulation materials 30 Measurement Standards 31 Bottom 32 Top 33 Protective film C Construction shape H Measurement standard body height R measurement reference point t1 Distance between the surface of the coating material and the imaginary plane t2 Coating thickness V Virtual plane

Claims

1. A measurement standard for measuring the thickness of a coating material applied to a target surface, It has the same function as the coating material, a bottom surface that is fixed to the target surface; The height from the bottom surface to the top is greater than the planned thickness of the coating material; Measurement reference body.

2. Made of substantially the same material as the coating material; The measurement standard according to claim 1 .

3. The coating material is a thermal insulating material. The measurement standard according to claim 1 or 2.

4. The insulation material is a foamed-in-place spray urethane. The measurement standard according to claim 3.

5. The top surface is a plane parallel to the bottom surface, A protective film is provided on the top. The measurement reference body according to any one of claims 1 to 4.

6. having a cylindrical or frustum shape; The measurement reference body according to any one of claims 1 to 5.

7. A method for measuring a coating thickness using the measurement standard body according to any one of claims 1 to 6, comprising the steps of: a step of fixing three or more of the measurement reference bodies having the same height from the bottom surface to the top surface to the target surface; acquiring a construction shape including a three-dimensional shape of the surface of the coating material and the top portion after the coating material is constructed on the target surface to which the measurement reference body is fixed; setting measurement reference points on the tops of three or more of the measurement reference bodies; calculating a thickness of the coating material based on the three-dimensional shape of the coating material surface and the three-dimensional coordinates of the measurement reference points; A coating thickness measuring method comprising the steps of:

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