Coating work management device, coating work management program, and railway vehicle coated using coating work management device

Abstract

To enable formation of appropriate coating film thickness on a coated object, when a worker manually performs coating.SOLUTION: A coating work management device 10 includes a measuring unit 120 for measuring a position and an attitude with respect to a coated surface 22 of a coating gun 100, and a coating work management unit 130 for calculating formed film thickness distribution. The coating work management unit 130 detects 3D data of a coated object, a distance between the coated surface and the coating gun, an inclination angle of the coating gun, and moving speed of the coating gun, and accurately calculates the film thickness distribution which is actually formed on the coated surface, on the basis of a model expression indicating a film thickness distribution pattern according to the shape of the coated surface in 3D shape data of the coated object. In a case in which operation of the coating gun by a worker is not normal, and in a case in which the film thickness distribution is in excessive or in shortage, appropriate work is assisted to be promoted by issuing an alarm to the worker during working.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a paint work management device and a paint work management program, and aims to realize a paint work management device that enables a worker to form an appropriate paint film thickness when manually painting an object to be painted, such as a railway vehicle. [Background technology]

[0002] Many structures, including buildings, are painted for the purpose of providing design and protection. In addition, for moving objects such as railroad cars and automobiles, the surface of the coating needs to be smooth in order to provide aesthetics and reduce aerodynamic resistance. Coatings may be single-layered, but they are often multi-layered in order to ensure the property of making the coating surface smooth. For example, when forming a coating on a metal surface, the process proceeds in the following steps: after roughening the metal surface by blasting or other methods, a rust-preventive primer is applied and dried, a putty is applied, dried, and polished to cover the unevenness of the metal surface and ensure smoothness, a primer is applied, dried, and polished to cover the fine unevenness of the putty surface, a middle coat is applied, dried, and polished, and a top coat is applied, dried, and polished to provide the design of the top surface.

[0003] Painting is generally done by hand or with an automated machine such as a robot. When painting is done by a worker, a spray, brush, roller, etc. are used, but it is difficult to quantitatively grasp the coating thickness in real time or immediately after painting, and it is highly dependent on the skill of the worker. For this reason, the coating quality varies depending on the skill of the worker, and it also takes time to train skilled workers.

[0004] On the other hand, when using a robot, the capital investment is expensive, and when using paint containing organic solvents, explosion-proof specifications are required, which further increases the capital investment.In addition, a large space is required to install the robot, and when heating the object to be painted, a process to move the robot away or a process to move the object to be painted and heat it are required, making it difficult to introduce.

[0005] In robot painting, there is a method for obtaining the paint film thickness distribution by simulation. For example, Patent Document 1 discloses a "paint film thickness simulation method" as a simulation technology. According to the simulation method of Patent Document 1, the film thickness distribution value at the paint gun position is obtained based on a reference pattern, and the film thickness distribution value is accumulated to obtain the film thickness distribution value of the object to be painted. Furthermore, Patent Document 2 discloses a "paint film thickness prediction method" as a simulation technology. According to the simulation method of Patent Document 2, a predicted paint film thickness is output to an output region of a spatial mesh that is set based on the three-dimensional shape of the surface to be painted, based on a model showing the fluid behavior of the carrier fluid and paint particles, and actual measurements of the particle state and fluid state in the input region of the spatial mesh. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2006-122830 A [Patent Document 2] JP 2010-274185 A Summary of the Invention [Problem to be solved by the invention]

[0007] In general, whether painting is done manually by an operator or using a robot, attention must be paid to the thickness of the paint film. If the painted film is thinner than a specified thickness (predetermined film thickness), problems such as weaker protection by the paint or failure to obtain the required aesthetic appearance may occur. If the film thickness is thicker than the specified thickness, the solvent may remain in the paint film and evaporate, causing problems such as blisters and cracks, or these problems may occur in combination, resulting in unevenness and other problems that impair the aesthetic appearance. In addition, using a large amount of paint leads to increased costs. To prevent these problems, it is important to ensure an appropriate film thickness over the entire surface of the object to be painted.

[0008] The simulation method shown in Patent Document 1 is a calculation method for obtaining a coating thickness value based on a determined coating condition. In reality, the deviation of the movement path of the coating machine from the assumed coating condition and the deviation from the specified position of the coated object are influenced by the variation in the position and inclination of the coating point within the coated surface due to the curved surface and uneven shape of the coated surface, which may cause a large deviation in the position and angle conditions between the coating machine and the coating point within the coated surface, and the error in the coating thickness calculation value may increase. As a countermeasure against this, there is a method of measuring the exact position and shape of the coated surface in three dimensions in advance, or a method of measuring the distance and angle of the coating gun to the coated object in real time during coating, but the former requires an increase in labor and is difficult to realize operationally, and the latter has the problem that the state of the coated surface (paint before drying and hardening) immediately after coating is unstable, making it technically difficult to realize.

[0009] An object of the present invention to address the above-mentioned problems is to provide a painting work management device and a painting work management program that enable an operator to achieve an appropriate paint film thickness by visualizing the paint film thickness while taking into account the movement path of the paint sprayer, any deviation from the designated position of the object to be painted, and the effects of the curved or uneven shape of the surface to be painted, when manually painting the object to be painted. Another object of the present invention to solve the above problem is to provide a railway car on which paint of an appropriate thickness has been applied using a painting work management device. [Means for solving the problem]

[0010] One example of the "painting work management device" of the present invention for solving the above problems is a painting work management device that manages a painting work in which painting is performed by spraying paint onto an object to be painted with a paint gun, and includes a measurement unit that measures the position and attitude of the paint gun relative to the surface of the object to be painted, and a painting work management unit that calculates the film thickness distribution formed on the surface of the object to be painted by spraying paint. The painting work management unit holds shape data of the object to be painted, specifies the distance of the paint gun to the surface to be painted of the shape data of the object to be painted, the tilt angle of the paint gun to the surface to be painted of the shape data of the object to be painted, and the moving speed of the paint gun, and calculates the film thickness distribution formed on the surface of the object to be painted based on information on the distance, tilt angle, and moving speed of the paint gun and information on a model formula that represents a film thickness distribution pattern according to the shape data of the object to be painted.

[0011] As an example of the "painting operation management method" of the present invention, there is a painting operation management method for managing a painting operation in which a paint gun sprays paint onto an object to be painted, comprising the steps of a measurement unit measuring the position and attitude of the paint gun relative to the surface to be painted of the shape data of the object to be painted, a painting operation management unit specifying the distance, tilt angle, and movement speed of the paint gun relative to the surface to be painted from the position and attitude of the paint gun, and a painting operation management unit calculating a film thickness distribution formed on the surface to be painted of the object to be painted based on information on the distance, tilt angle, and movement speed and information on a model formula that represents a film thickness distribution pattern corresponding to the shape of the surface to be painted in the shape data of the object to be painted, and further comprising a computer program for causing a computer to execute these steps. Effect of the Invention

[0012] According to the present invention, it is possible to provide a paint work management device and a paint work management program that can assist a worker in forming an appropriate paint film thickness during manual painting of a workpiece by visualizing the paint film thickness while taking into account the movement path of the paint applicator, the deviation of the workpiece from a predetermined position, and the effects of the curved surface and uneven shape of the workpiece, and to provide a railway car painted using the paint work management device. In addition, since areas of the workpiece surface where paint is insufficient are identified and displayed during work, the worker can easily apply additional paint, and it is possible to reduce variation in paint quality due to the worker's level of skill and provide a high-quality workpiece. Problems, configurations and effects other than those described above will become apparent from the following description of the embodiments. [Brief description of the drawings]

[0013] [Figure 1] FIG. 2 is a diagram showing the relationship between a coating machine and an object to be coated during a coating operation according to an embodiment of the present invention. [Diagram 2] 1 is a block diagram showing a configuration of a paint work management device 10 according to an embodiment of the present invention. [Diagram 3] 3 is a block diagram showing a detailed configuration of the paint work management unit 130 of FIG. 2. [Figure 4] 10 is a diagram for explaining coordinate data of an object to be painted when the position of the object to be painted is specified by a marker 30. FIG. [Diagram 5] 5 is a flowchart showing a procedure for aligning shape data of a workpiece to a position of the workpiece in a measurement coordinate system of a measurement unit. [Figure 6A] 2 is an explanatory diagram showing the inclination angle (horizontal angle) of a paint gun 100 with respect to a surface 22 to be painted. FIG. [Figure 6B] 3 is an explanatory diagram showing the inclination angle (vertical angle) of a paint gun 100 with respect to a surface 22 to be painted. FIG. [Figure 6C] 1 is an explanatory diagram showing the three-dimensional position coordinates of the paint gun tip 105 at various times, and the painted surface coordinates in the direction of each paint gun tip directional vector. [Figure 7] FIG. 4 is an explanatory diagram showing types of coating patterns. [Figure 8] FIG. 2 is an explanatory diagram showing the trajectory of a tip 105 of a coating gun. [Figure 9A] FIG. 2 is an explanatory diagram showing the tendency of the coating thickness pattern depending on the difference in the distance between the coating gun 100 and the surface 22 to be coated. [Figure 9B] FIG. 11 is an explanatory diagram showing the tendency of the coating thickness pattern depending on the moving speed of the coating gun. [Figure 9C] 1 is an explanatory diagram showing the tendency of the coating thickness pattern depending on the difference in the vertical inclination between the coating gun 100 and the surface 22 to be coated. FIG. [Figure 10A] FIG. 2 is an explanatory diagram showing the tendency of the coating film thickness pattern when the surface 22 to be coated is a flat surface. [Figure 10B] FIG. 2 is an explanatory diagram showing the tendency of the coating film thickness pattern when the surface 22 to be coated is a curved surface. [Figure 11A] FIG. 4 is an explanatory diagram showing a coating thickness distribution in a coating pattern in a pattern width direction. [Figure 11B] FIG. 2 is an explanatory diagram showing the geometric relationship between the tip of the paint gun and the surface to be painted when the surface to be painted 22 has a curved shape within the pattern width region and the paint gun is tilted vertically. [Figure 12] FIG. 13 is a diagram showing a painting condition management table 160 according to paint and painting gun conditions. [Figure 13] FIG. 13 is a diagram showing a display example of a film thickness distribution image. [Figure 14] 2 is a flowchart showing the flow of a painting operation according to an embodiment of the present invention. [Figure 15] 15 is a flowchart showing the detailed procedure of S113 in FIG. 14. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. However, the present invention is not to be interpreted as being limited to the description of the embodiment shown below. Those skilled in the art will easily understand that the specific configuration can be changed without departing from the concept or gist of the present invention. In addition, in each drawing for explaining the embodiment, the same components are given the same names and symbols as much as possible, and repeated explanations are omitted.

[0015] A manual painting method using a painting operation management device according to an embodiment of the present invention will be described using an example in which the object to be painted is a railway vehicle 20. FIG. 1 is a diagram showing the positional relationship between a paint gun 100 and the object to be painted during painting work. A painter having a paint gun 100, a paint supply machine 110, and a hose 106 is used as a painting facility for painting the railway vehicle 20. The paint supply machine 110 uses a pump to suck up liquid paint stored in a paint tank (not shown) and supplies it to the paint gun 100 via the hose 106. In addition, high-pressure air is also supplied to the paint gun 100 by a compressor (not shown). Here, the amount of paint supplied from the paint supply machine 110 to the paint gun 100, the amount of paint sprayed from the paint gun 100, the spray direction, etc. are managed by a painting operation management device 10 described later in FIG. 2.

[0016] The railcar 20 shown in FIG. 1 is one car of a train or steam train operated with multiple cars, and in the example of FIG. 1, an operator is shown painting the left side of the car with a paint gun 100 (however, the operator is not shown). The paint gun 100 can be a well-known pneumatic type that has been widely used in the past, and is configured so that the operation of the paint gun 100 (the tilt angle with respect to the surface to be painted, and the movement speed of the paint gun) and the relative position with respect to the surface to be painted can be identified. Here, multiple markers 30 are attached to the paint gun 100, and the tip 105 of the paint gun 100 relative to the markers 30 is detected. Multiple cameras 121a-121j are arranged around the railcar 20 to detect the position of the paint gun 100.

[0017] Three markers 30a to 30c are provided on the upper left side of the railcar 20, and three markers 30e to 30f are provided on the lower left side. In the example of FIG. 1, three markers 30 are provided on the paint gun 100, but any number of markers 30 may be provided as long as it is three or more. The markers 30 serve as indicators for accurately detecting the position of the paint gun 100, and mainly measure three things: the distance of the paint gun 100 to the surface 22 of the workpiece 20 to be painted, the inclination angle of the paint gun 100 to the surface (surface 22) of the workpiece 20 to be painted, and the travel speed of the paint gun 100. For example, a visually identifiable sticker-type mark, an optically luminous device, or an optically reflective member can be used as the marker 30.

[0018] The cameras 121a to 121j are a plurality of optical input devices fixed to a mounting frame 40 so as to be aligned along the surface 22 to be painted of the railcar 20 (the left side in the example of FIG. 1), and capture moving images and transmit digital images in real time to the paint work management device 10 described later in FIG. 2. In FIG. 1, a horizontal mounting frame 40 extending in the X direction is provided, but the frame 40 may have not only one stage but also multiple stages in the vertical direction, and the number of cameras may be further increased. The distance between the cameras 121a to 121j and the surface 22 to be painted is set at a position that is greater than the distance between the paint gun tip 105 and the surface 22 to be painted during painting work, and the cameras 121a to 121j are preferably positioned so that they can capture both the paint pattern 107 and the paint gun tip 105 during work.

[0019] The paint gun 100 is an air spray type that sprays paint by spraying the supplied paint with air. The paint is supplied to the paint gun 100 from a paint supplying machine 110, and the paint is atomized by spraying pressurized air (high pressure air) supplied from a compressor or the like (not shown) through a hose 106, and the atomized paint is sprayed onto the surface 22 to be painted. As shown in the enlarged view at the bottom of FIG. 1, the paint gun 100 has a handle 101 that an operator holds and a trigger lever 102. In order to realize the paint work management device 10 according to this embodiment (described later in FIG. 2), the paint gun 100 may be configured to include a sensor for optically identifying the marker 30 and a three-axis sensor (not shown) for detecting in which direction the tip 105 of the paint gun 100 faces among the three axial directions of X, Y, and Z. Alternatively, the paint gun 100 may be configured in the same manner as in the past, and the operation of the paint gun 100 may be detected by analyzing a plurality of images acquired by the cameras 121a to 121j. Here, the +Z direction indicates a direction moving away from the surface 22 to be coated in a horizontal and vertical direction.

[0020] 2 calculates the three-dimensional position coordinates (x, y, z) of the paint gun tip 105, the tip direction vector (a, b, c) indicating the orientation of the paint gun 100, and the normal vector (α, β, γ) at the intersection coordinates (x', y', z') (hereinafter referred to as painting center position coordinates) of the paint gun tip direction vector (a, b, c) with the surface to be painted 22. The operating state of the paint gun 100 is detected in detail from this coordinate information and vector information.

[0021] The paint pattern 107 formed in each time unit is, for example, an ellipse. When a painter paints the side of the railcar 20, he places the paint gun 100 several hundred mm away from the paint center 107a of the surface to be painted (surface of the railcar 20), and paints by moving the paint gun 100 back and forth in the horizontal direction (+X direction in FIG. 1) while also moving it vertically (+Y direction in FIG. 1). By operating the paint gun 100, painting is performed over a certain range in the horizontal direction (a range of several hundred mm wide from the top to the bottom of the vehicle), and when this is completed, the worker moves in the longitudinal direction of the vehicle (X direction in FIG. 1) and paints the entire side of the vehicle by repeating the same paint gun operation. The painting method is not limited to the air spray method, and any form such as an air gun, airless gun, or electrostatic gun may be used.

[0022] 2 is a block diagram showing the configuration of a paint work management device 10 according to an embodiment of the present invention. The paint work management device 10 is configured to include a measurement unit 120 and a paint work management unit 130. The hardware and software configuration of the paint work management unit 130 can be realized by a general information processing device such as a PC (Personal Computer) 140 described later in FIG. 3. The measurement unit 120 measures the operation of the paint gun 100 during painting and its position relative to the surface 22 to be painted. The paint work management unit 130 analyzes the measurement results obtained by the measurement unit 120, calculates and analyzes the film thickness distribution formed on the surface 22 to be painted from the analysis results, and provides instructions to an operator based on the analysis results.

[0023] The measurement unit 120 is installed in a space where painting work is performed (hereinafter, painting work space), and includes multiple position detection sensors 121 (cameras 121a to 121j shown in FIG. 1) and a marker analysis unit 122. The position detection sensor 121 is an optical sensor including a known camera means such as a CCD or CMOS. As another configuration, light (visible light or infrared light) is irradiated from the position detection sensor 121, and the light reflected by the marker 30 is detected by the position detection sensor 121, or the marker 30 itself can be a light emitting body, and the light directly emitted by the marker 30 can be detected by the position detection sensor 121. The optical signals detected by two or more of the multiple position detection sensors 121a to 121j are analyzed by the marker analysis unit 122 to calculate the paint gun tip direction vector (a, b, c) and the intersection coordinates (x', y', z') with the surface 22 to be painted.

[0024] The painting operation management unit 130 is composed of a data memory unit 131 which imports and holds shape data of the workpiece 20 from the outside, a shape data position adjustment unit 132 which aligns the shape data of the workpiece to the position of the workpiece in the measurement coordinate system of the measurement unit, a paint gun operation calculation unit 133 which calculates the operation of the paint gun 100 relative to the surface to be painted based on the shape data of the workpiece, a paint surface shape analysis unit 134 which analyzes the shape of the surface to be painted from the shape data information of the workpiece, a film thickness calculation unit 135 which calculates the film thickness distribution formed on the surface to be painted from the analysis results of the paint surface shape analysis unit 134 and the analysis results of the paint gun operation, a painting condition analysis unit 136 which determines the contents of instructions to be given to the operator based on the calculation results of the film thickness calculation unit 135, and a painting condition / work instruction unit 137 which displays the contents of instructions to the operator and the film thickness distribution based on the film thickness calculation unit 135 and the painting condition analysis unit 136. The data acquired and stored by the data storage unit 131 includes a painting condition management table and information on a model formula that shows the painting surface of the object in three dimensions.

[0025] Each part (131-137) in the painting operation management unit 130 can be realized by software using a computer program that causes a processor such as a PC to execute the function of each part. However, as long as the functions shown in Fig. 2 can be executed, a system that executes a computer program externally using a cloud system or the like may also be used.

[0026] FIG. 3 is a block diagram showing a detailed configuration of the paint work management unit 130 of FIG. 2. In the paint work management unit 130, a central processing unit (CPU) 141 of a personal computer (PC) 140 executes a plurality of computer programs (151 to 155) to realize each function. The PC 140 has a primary main storage device 142 such as a semiconductor memory, an auxiliary storage interface (hereinafter, the interface is referred to as "I / F") 143 that enables input and output of data to the auxiliary storage device 150 via a data bus, a network I / F 144, and an input / output I / F 145 that visually displays information for workers, supervisors, etc. and receives input operations from workers, supervisors, etc., and these are connected by a data bus. In this embodiment, the CPU 141 is given as an example of a processor, but other semiconductor devices may be used as long as they are the main body that executes the predetermined processing.

[0027] The main memory 142 is typically mainly composed of a volatile memory such as a RAM, and stores the programs executed by the CPU 141, data to be referenced, and data calculated by the CPU. The auxiliary memory I / F 143 is an interface for connecting the auxiliary memory 150. The auxiliary memory 150 is a large-capacity secondary memory device, and can be configured using a known non-volatile memory device, such as an HDD (Hard Disk Drive) or an SSD (Solid State Drive). A plurality of programs are stored in the auxiliary memory 150, and when each program is executed, it is read out into the main memory 142 composed of a RAM or the like. The auxiliary memory 150 may be configured to be built into the painting work management unit 130.

[0028] The programs stored in the auxiliary storage device 150 are programs that realize the functions of each section (132-136) in Fig. 2, and include a shape data position adjustment program 151, a paint gun operation calculation program 152, a coated surface shape analysis program 153, a film thickness calculation program 154, and a coating condition analysis program 155. Information required for the execution of each program is also stored. Here, a painting condition management table 160 and coated object shape data 170 are stored. The auxiliary storage device 150 also stores work record data and various programs and data (none of which are shown) processed by the CPU 141.

[0029] The network I / F 144 is an interface for connecting the painting work management device 10 to external devices via a network, and the PC 140 is connected by wire or wirelessly to various external devices, for example, the measurement unit 120 shown in Fig. 2, a wearable terminal such as an HMD (Head Mounted Display) 147 that displays the film thickness distribution calculation results and instructions to the worker, and other systems in the factory. By wearing the HMD 147, the worker performing the painting work can visually obtain various information from the painting work management unit 130.

[0030] The input / output I / F 145 is connected to an input device 148 for inputting data such as painting conditions to the coating work management device, and an output device 149 for outputting output data from the PC 140 for each screen (painting condition input screen, device operation buttons, film thickness distribution calculation result display screen, etc.) of the control software for controlling the coating work management device. The input device 148 can be configured with a known keyboard and mouse, and the output device 149 can be configured with a known monitor, but the input device 148 and the output device 149 may be configured with, for example, a touch panel. The number of output devices 149 and HMDs 147 is arbitrary, and they may be combined into one of them. Furthermore, the output device 149 may be a small matrix display device, such as a touch-type liquid crystal display, provided on the top surface of the coating gun 100, or a mobile terminal owned by the operator.

[0031] The paint condition analysis program 155 calculates the film thickness distribution formed on the painted surface of the object based on information on the distance, tilt angle, and travel speed of the paint gun 100 and information on a model formula that represents a film thickness distribution pattern corresponding to the shape of the surface 22 to be painted of the object (railroad car 20) in the shape data of the object to be painted, and judges whether the film thickness distribution formed on the painted surface is appropriate. Here, the shape data of the object to be painted (railroad car 20) can use a three-dimensional model based on three-dimensional CAD data constituting the design drawings, and by aligning the three-dimensional model of the railroad car 20 to the position of the railroad car 20 in the xyz coordinate system set in the painting space, the shape of the surface 22 to be painted can be grasped in detail using the three-dimensional model of the railroad car 20 aligned by CPU 141.

[0032] FIG. 4 is a diagram for explaining the coordinate data of the object to be painted when the position of the object to be painted is specified by the marker 30. An xyz coordinate system (z-axis is the axis perpendicular to the surface to be painted, x-axis is the horizontal axis on the surface to be painted, and y-axis is the vertical axis on the surface to be painted) is set on the surface to be painted 22. As a method for detecting the position of each marker by the position detection sensor 121, the position detection sensor may irradiate light (visible light or infrared light) to the paint gun 100, and the position detection sensor 121 may detect a plurality of lights reflected by the retroreflective markers 30a-30g that reflect the light in the irradiation direction, or the markers 30a-30g themselves may be light-emitting bodies, and the position detection sensor 121 may detect the lights directly emitted by the markers 30a-30g. It is preferable to remove the markers 30a-30g before starting the painting work, and the adhesion part to the vehicle may be made of a sealant. Each coordinate of the position detection sensor 121 is previously set as a three-dimensional position coordinate (x, m k ,ym k ,zm k ); (0≦k≦n, n: number of markers) is acquired by the CPU 141. The optical signals from the markers 30 detected by the multiple position detection sensors 121 are analyzed by the marker analysis unit 122 of the measurement unit 120, and the three-dimensional position coordinates (x,m,k ,ym k ,zm k ); (0≦k≦n, n: number of markers) can be calculated.

[0033] Each characteristic point on the surface 22 to be coated is represented by coordinate values ​​(xm k ,ym k ,zm k ) is specified as a reference position, and shape data for the reference position is acquired by the CPU 141. The CPU 141 acquires the coordinate values ​​(xd k ,yd k ,zd k );(0≦k≦n), by taking into consideration shape data that can be obtained from the design data of the railway vehicle 20, such as the positions of the doors 25 and windows 26, it is possible to precisely identify the range and shape of the surface 22 to be painted.

[0034] 5 shows the procedure for aligning the shape data of the object to be painted with the position of the object to be painted. Before painting, the object to be painted (surface to be painted 22 of the railway vehicle 20) is aligned with the shape data of the object to be painted held by the painting work management device 10. First, characteristic points on the surface to be painted 22 (for example, in the case of the railway vehicle 20, positions where the coordinates of the side windows and the center of the opening of the entrance / exit can be specified) are selected, and multiple markers 30 are attached to each characteristic point on the surface to be painted (step 200, in the figure, "step" is illustrated by the letter "S"). Next, the CPU 141 reads the shape data (3D model data) 157 of the object to be painted 20 from the auxiliary storage device 150 to the main storage device 142 (step 201), and registers the coordinate values ​​of each characteristic point on the surface to be painted of the shape data (step 202).

[0035] Next, the CPU 141 detects each position of the marker 30 using the multiple position detection sensors 121 of the measurement unit 120 installed in the painting work space (step 203). The optical signal detected by any of the multiple position detection sensors 121a to 121g is analyzed by the marker analysis section 122 of the measurement unit 120 to obtain three-dimensional position coordinates (x, m, k ,ym k ,zm k) can be calculated.

[0036] Next, the marker analysis unit 122 calculates the coordinate values ​​(xm k ,ym k ,zm k ) and the coordinate values ​​(xd k ,yd k ,zd k ); (0≦k≦n), corresponding point matching is performed to calculate a coordinate transformation matrix for the shape data that minimizes the difference between the coordinate values ​​of each characteristic part of the actual object to be painted and the coordinate values ​​of the shape data corresponding to each characteristic part (step 204). Additionally, the shape data position adjustment unit 132 uses the coordinate transformation matrix calculated in step 204 to align the shape data of the object to be painted with the object position in the measurement coordinate system of the measurement unit 120 (step 205). By the above processing, the actual object to be painted 20 can be replaced with the shape data of the object to be painted, making it possible to numerically express the position and shape of the surface to be painted 22 in the measurement coordinate system of the measurement unit 120.

[0037] When an operator is painting, the position of each marker is detected at regular short time intervals (Δt) by the multiple position detection sensors 121 of the measurement unit 120 at various times during painting. Furthermore, the optical signals detected at regular time intervals (Δt) are analyzed by the marker analysis section 122 of the measurement unit 120 to calculate the three-dimensional position coordinates (x, y, z) of the paint gun tip 105 in the painting work space at various times and the paint gun tip direction vector (a, b, c) indicating the orientation of the paint gun tip 105. The paint gun tip direction vector (a, b, c) has the position of the paint gun tip 105 as its starting point.

[0038] The paint gun operation calculation section 133 of the paint work management unit 130 calculates the distance l of the paint gun tip 105 from the surface to be painted 22, the inclination angle (horizontal angle φ, vertical angle θ) of the paint gun tip 105 from the surface to be painted 22, the movement speed v of the paint gun 100, and the horizontality of the trajectory of the paint gun 100 and the spacing of the trajectory of the paint gun 100, which represent the state of the paint gun operation, from the three-dimensional position coordinates (x, y, z) of the paint gun tip 105 calculated by the marker analysis section 122, the paint gun tip direction vector (a, b, c), and the normal vector (α, β, γ) at the surface to be painted coordinates (x', y', z') in the direction of the paint gun tip direction vector (a, b, c) (hereinafter referred to as the painting center position coordinates).

[0039] Next, a method for setting an xyz coordinate system on the surface 22 to be painted and calculating the distance l of the paint gun tip 105 to the surface 22 to be painted, the inclination angle (horizontal angle φ, vertical angle θ) of the paint gun tip 105 to the surface 22 to be painted, and the movement speed v of the paint gun 100 will be explained using Figures 6A, 6B, and 6C.

[0040] 6A shows a plan view (xz plane) of the paint gun 100 and the surface 22 to be painted as viewed from the y-axis direction in the coordinate system, and the angle of the paint gun tip 105 with respect to the horizontal cross section of the surface 22 to be painted is the horizontal angle φ shown in the figure. The orthogonal projections of the paint gun tip direction vector (a, b, c) and the normal vector (α, β, γ) of the surface to be painted in the direction of the paint gun tip direction vector onto the xz plane are (a, 0, c) and (α, 0, γ), respectively, as shown in the figure, and the horizontal angle φ is expressed as the angle formed by these vectors and can be calculated using formula (1).

[0041]

number

[0042]

number

[0043]

number

[0044]

number

[0045] Next, the trajectory of the paint gun 100 (horizontal degree of the trajectory and the interval between the trajectories) will be described with reference to Figs.

[0046] The shape of the paint pattern shown in Fig. 7 changes depending on the settings of the paint gun 100. The paint gun 100 is a widely used hand spray gun, and can form three types of paint patterns, a rectangular pattern 400, an elliptical pattern 401, and a circular pattern 402, depending on the state of air spraying from an air outlet provided adjacent to the paint nozzle. When the paint thickness pattern is a rectangular pattern 400 or an elliptical pattern 401, the width in the major axis direction is called a pattern width 403, and during painting, the paint gun 100 is moved in a direction perpendicular to the direction of the pattern width 403 (the paint line direction), and in the case of a circular pattern, paint is continuously sprayed while moving the paint gun 100 in either the vertical or horizontal (horizontal or vertical) direction.

[0047] 8 shows an example of the movement trajectory of the tip position of the paint gun 100. When the paint gun 100 is painting the side (surface to be painted 22) of the railcar 20, the paint gun 100 is basically moved horizontally in the +X direction, and the trajectory 500a of the paint gun tip 105 is in the direction shown in the figure. When painting is completed up to the end of the painting line in the +X direction, paint spraying is stopped and the paint gun 100 is moved a certain distance in the direction perpendicular to the painting line direction (-Y direction) as shown by arrow 500b, and then painting is performed in the -X direction as shown by arrow 500c. When painting is completed up to the starting point in the X direction, paint spraying is stopped and the paint gun 100 is moved a certain distance in the vertical direction (-Y direction) as shown by arrow 500d, and paint spraying is resumed again to continue painting to the next painting line 500e.

[0048] In each of the coating lines 500a, 500c, 500e, etc., the CPU 141 (see FIG. 3) executes the coating gun operation calculation program 152 to fit a line 502 (Y=aX+b, a: line gradient, b: y-intercept) to a data string 501 of coordinates (x', y') in the surface to be coated in the direction of the coating gun tip direction vector (a, b, c), and calculates the gradient a and the y-intercept b. Furthermore, the angle (ψ) that the fitting line 502 in the coating line makes with the vertical direction of the pattern width is defined as the horizontality 503 of the trajectory. The distance between the fitting line 504 in the coating line immediately before the coating line and the coordinates (x', y') in the surface to be coated in the direction of the coating gun tip direction vector is defined as the trajectory distance 505 of the coating gun 100. This trajectory distance 505 of the coating gun 100 is generally called the painting distance, and the recommended value differs depending on the shape of the pattern. Normally, it is recommended to paint 3 / 4 of the pattern width 403 (see Figure 7) for a rectangular pattern, 2 / 3 for an elliptical pattern, and 1 / 2 for a circular pattern. By painting at the recommended intervals, the painter can obtain a nearly uniform coating thickness on the paint surface.

[0049] As described above, painting is performed while moving the paint gun 100 generally in a parallel direction from top to bottom, and the painting work is repeated as shown by trajectories 504 and 503. The horizontality of the trajectory of the paint gun 100 can be calculated from equation (5) using the slope a of the equation for fitting line 502. In addition, the trajectory interval 505 of the paint gun 100 is calculated from the Y coordinate (y") obtained by substituting the X coordinate (x') on the surface to be painted in the direction of the paint gun tip direction vector of the painting line into the equation for fitting line 504 for the painting line immediately preceding that painting line, and the Y coordinate (y') on the surface to be painted in the direction of the paint gun tip direction vector of that painting line, using equation (6).

[0050]

number

[0051]

number

[0052] The film thickness calculation section 135 of the paint work management unit 130 calculates the film thickness distribution formed on the surface to be painted 22 from information on the distance l of the paint gun tip 105 from the surface to be painted 22 calculated by the paint gun operation calculation section 133, the inclination angle (horizontal angle: φ, vertical angle: θ) of the paint gun tip 105 from the surface to be painted 22, and the movement speed v of the paint gun 100, as well as information on the paint supply amount detected by the paint supply machine 110.

[0053] Here, we will explain the tendency of the film thickness distribution pattern to change with changes in the distance of the tip 105 of the paint gun 100 from the surface to be painted 22, the inclination angle of the tip 105 of the paint gun 100 from the surface to be painted 22, and the movement speed of the paint gun 100, using Figures 9A, 9B, and 9C.

[0054] Fig. 9A shows the relationship between the distance of the paint gun 100 from the surface 22 to be painted and the paint film thickness pattern, Fig. 9B shows the relationship between the moving speed of the paint gun 100 and the paint film thickness pattern, and Fig. 9C shows the relationship between the vertical inclination with respect to the surface 22 to be painted and the paint film thickness pattern. The figures show a paint pattern 107 produced by the paint gun 100, but as shown in the left diagram of Fig. 9A, if the distance between the paint gun 100 and the surface 22 to be painted is short, the paint film thickness pattern formed on the surface 22 to be painted is small, so the paint is dense and the film thickness is large, and as shown in the right diagram, if the distance between the paint gun 100 and the surface 22 to be painted is long, the paint film thickness pattern formed on the surface 22 to be painted is large, so the paint is dispersed and the film thickness is small.

[0055] Furthermore, as shown in the diagram on the right side of Figure 9B, when the paint gun 100 is moved at a high speed, the paint transfer efficiency (the ratio between the mass of the paint used and the mass of the paint actually adhered to the object) decreases due to the influence of the air flow, resulting in a smaller paint film thickness. Conversely, when the paint gun 100 is moved at a low speed, as shown in the diagram on the left side, the paint transfer efficiency increases and the film thickness increases.

[0056] Furthermore, as shown in FIG. 9C, when the paint gun 100 is tilted vertically relative to the surface 22 to be painted, the paint film thickness is greater where the paint gun 100 is closer to the surface 22 to be painted, and is smaller where the paint gun 100 is farther from the surface 22 to be painted, so that the film thickness formed on the surface 22 to be painted is uneven.

[0057] Furthermore, the tendency of the coating thickness pattern when the surface to be coated is curved will be described with reference to Fig. 10. Fig. 10A shows a coating thickness pattern 701 and a thickness distribution 702 in the pattern width direction when the surface to be coated 22 is flat (the normal vector 700 at each position on the surface to be coated is constant), and Fig. 10B shows a coating thickness pattern 704 and a thickness distribution 705 in the pattern width direction when the surface to be coated 23 is curved (the normal vector 700 differs depending on each position on the surface to be coated). In Fig. 10A and Fig. 10B, the position of the coating center 107a on the surface to be coated relative to each coating gun tip 105 is the same, but in Fig. 10B, as each position on the surface to be coated moves away from the coating center 107a, the inclination angle 703 of each normal vector 700 relative to the direction vector of the coating gun tip 105 increases, so the coating efficiency on the surface to be coated in Fig. 7B is smaller than that in Fig. 7A. For this reason, in the film thickness distribution 705 of FIG. 10B, the film thickness rapidly decreases toward the ends of the pattern width compared to the film thickness distribution 702 of FIG. 10A, and the paint film thickness pattern 704 of FIG. 10B tends to be smaller in the vertical direction compared to the paint film thickness pattern 701 of FIG. 10A.

[0058] In consideration of the above trends, the painting work management device 10 in this embodiment holds a model equation that represents a film thickness distribution pattern according to the painting conditions (the distance of the paint gun tip 105 from the position of the painting center 107a of the surface 22 to be painted, the inclination angle of the paint gun tip 105 with respect to each local area of ​​the surface 22 to be painted, and the movement speed of the paint gun 100), and the model equation can be expressed by equations (7) to (14).

[0059]

number

[0060]

number

[0061]

number

[0062]

number

[0063]

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[0064]

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[0065]

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[0066]

number

[0067] <Description of each function and parameter> P s (x s ) : Film thickness distribution function on the coated surface P0(x0): Reference film thickness distribution function under standard conditions (Polynomial approximation of film thickness measured under standard conditions) α(v): Coating efficiency depending on the paint gun moving speed β(l): Coating efficiency depending on the distance of the paint gun tip to the surface to be painted γ(l): Pattern width expansion rate depending on the distance of the paint gun tip to the painted surface T(x0,θ s ) : Coordinate transformation function of the surface to be painted x0: Position coordinate in the pattern width direction of the reference film thickness distribution x s : Pattern width direction position of each local area on the painted surface (starting point of paint center) y s : Surface normal direction position of each local area on the painted surface (starting point of paint center) v: Paint gun movement speed l0: Painting distance from the center of the painting surface θ: Vertical inclination angle of the paint gun at the center of the paint on the surface to be painted θ s : Position of the surface to be painted (x s ,y s ) The angle of the spray gun relative to the normal x, y, z: Paint gun tip position coordinates x', y', z': Paint center position coordinates a, b, c, d, e, f, g, h, o, p, q, r: Coefficients (calculated from experimental data)

[0068] The above model formula will be explained below with reference to Figures 11A and 11B. Formula (7) represents the film thickness distribution in the pattern width direction formed around the position coordinates (x', y', z') of the painting center 107a when the paint gun is moved at a constant speed. Figure 11A shows the film thickness distribution 800 in the pattern width direction under standard painting conditions, and Figure 11B shows the geometric relationship between the paint gun and the surface to be painted when the surface to be painted 22 has a curved shape within the pattern width region and the paint gun is tilted vertically. In addition to the information on the vertical tilt angle of the paint gun 100, the paint work management unit calculates the film thickness distribution taking into account the change in the film thickness distribution pattern caused by the change in the tilt angle in each local region of the surface to be painted in the pattern width from the information on the shape data (3D model data) of the painted object held by the painting work management unit.

[0069] The film thickness distribution function in the pattern width direction shown by equation (7): P s (x s) is the standard thickness distribution function P0(x0) which represents the thickness distribution pattern at each standard value (hereinafter, standard conditions) of the distance of the paint gun tip 105 from the coating center of the surface to be coated, the tilt angle of the paint gun tip 105 with respect to each local area of ​​the surface to be coated, and the movement speed of the paint gun 100. This standard thickness distribution function, a function α(v) which represents the influence of the movement speed of the paint gun 100: v shown in formula (8), a function β(l) which represents the influence of the distance of the paint gun tip 105 from the coating center of the surface to be coated: l shown in formula (9), a pattern width expansion rate γ(l) due to the distance of the paint gun tip 105 from the coating center of the surface to be coated: l shown in formula (10), and a vertical tilt angle θ of the paint gun 100 with respect to each local area 801 within the pattern width of the surface to be coated shown in formula (11). s The function that expresses the effect of: T(x0,θ s )

[0070] In addition, each of the functions (7) to (11) can be expressed as a polynomial function using multiple model parameters (a, b, c, d, e, f, g, h, o, p, q, and r) that correspond to changes in the painting conditions. For this reason, as shown in Fig. 12, the painting work management device 10 holds a painting condition management table 160 that indicates model parameter values ​​that correspond to combinations of these paints and paint gun conditions, and selects a model parameter set according to the paints and paint gun conditions during painting.

[0071] The reference film thickness distribution function may be determined by actually measuring the film thickness distribution in the pattern width direction when coating is performed under the above-mentioned standard conditions using a film thickness meter and determining an approximation equation for the actual measurement results, or by calculation from a simulation of the coating film thickness under the above-mentioned standard conditions.

[0072] In addition, the paint condition analysis section 136 of the paint work management unit 130 determines the operation state of the paint gun 100 relating to the distance of the paint gun tip 105 from the surface to be painted, the tilt angle of the paint gun tip 105 from the surface to be painted, the movement speed of the paint gun 100, the horizontality of the paint gun 100's orbit, and the spacing of the paint gun 100's orbit at each point during painting, and the film thickness distribution state, based on the distance of the paint gun tip 105 from the surface to be painted, the tilt angle of the paint gun tip 105 from the surface to be painted, the movement speed of the paint gun 100, the horizontality of the paint gun 100's orbit, and the spacing of the paint gun 100's orbit at each point during painting calculated by the paint gun operation calculation section 133, and the film thickness distribution data formed on the painted surface of the object calculated by the film thickness calculation section 135.

[0073] For this reason, as shown in FIG. 12, the painting operation management device 10 holds a painting condition management table 160. The painting condition management table 160 holds values ​​of the appropriate ranges of the paint gun operation (the distance of the paint gun tip 105 from the surface 22 to be painted at each time of painting, the tilt angle of the paint gun tip 105 from the surface to be painted, the moving speed of the paint gun 100, the horizontality of the trajectory of the paint gun 100, and the interval of the trajectory of the paint gun 100) according to the paint and paint gun conditions, and the appropriate ranges of the paint film thickness. Based on the appropriate ranges, the CPU 141 judges whether the specified paint gun operation state and the film thickness distribution state are each within the appropriate range. Note that each of the above appropriate ranges is determined by conducting a painting test in advance and determining the range where there are no painting defects (for example, dripping, smearing, etc.) under each paint and paint gun condition.

[0074] The coating condition management table 160 has fields for an ID number 161 , a paint type 162 , a coating gun model 163 , a coating pattern width 164 , a paint supply flow rate 165 , an air pressure 166 , a model parameter set 167 , and an optimum value range set 168 .

[0075] The ID number 161 stores numbers that identify each paint and paint gun condition, starting from 1. The paint type 162 stores paint product name information. The paint gun model 163 stores the model name of the paint gun 100. The paint pattern width 164 stores the paint pattern width in units of "mm". The paint supply flow rate 165 stores the flow rate of paint supplied to the paint gun in units of "cc / min". The air pressure 166 stores the air pressure value in units of "MPa". The model parameter set 167 stores the values ​​of the model parameters (a, b, c, d, e, f, g, h, o, p, q, r) separated by commas. The optimum value range set 168 stores, (1) The distance (mm) of the paint gun 100 from the center of the surface to be painted, (2) the inclination angle (°) of the paint gun 100 relative to the surface to be painted, (3) The moving speed of the paint gun 100 (mm / s), (4) Horizontality of the painting track (°), (5) Paint track spacing (mm), (6) The appropriate ranges (lower and upper limits) for the paint film thickness (μm), are stored in the order of (1) to (6), separated by commas, and a "-" is inserted between the lower and upper limits of each appropriate range.

[0076] The painting condition / work instruction section 137 of the painting work management unit 130 outputs the paint gun operation and film thickness distribution state (within appropriate range, outside appropriate range) determined by the painting condition analysis section 136 to a wearable terminal such as an HMD 147 that can be worn by the worker, and instructs the worker during the painting work. The teaching method may be to display characters on the terminal screen, but it is also effective to emit an alert sound when the range is outside the applicable range or to display an indicator such as a lamp on the terminal screen and change the display color depending on whether the range is within the applicable range or not (for example, display green if within the applicable range and red if outside the applicable range) so that the worker can easily recognize the range while painting.

[0077] At the same time, the coating status / work instruction section 137 of the coating work management unit 130 sequentially converts the coating thickness distribution results in the pattern width direction at the coordinates (x', y') on the surface to be coated in the coating gun tip direction vector direction calculated by the coating thickness calculation section 135 into a two-dimensional or three-dimensional coating thickness distribution image, and outputs it to a wearable device such as an HMD 147 for display.

[0078] The film thickness distribution image (two-dimensional distribution image) output to the HMD 147 and / or the output device 149 will be described below with reference to Fig. 13. In the film thickness distribution image, the horizontal direction corresponds to the X axis (paint line direction) of the painted area 1000 on the surface to be painted, and the vertical direction corresponds to the Y axis (pattern width direction) of the painted area 1000, and the value obtained by dividing the painted area range (width: W (mm), height: H (mm)) of the surface to be painted by the number of pixels (n, m) on each axis of the film thickness distribution image (vertical direction: W / n (mm), horizontal direction: H / m (mm)) becomes the spatial resolution of the image (dimension of one pixel).

[0079] The thickness distribution image is generated by converting the thickness distribution 800 in the pattern width direction at the coordinates (x', y') on the surface to be painted in the direction of the paint gun tip direction vector calculated by the thickness calculation unit 135 into a gradation value for each pixel, and assigning the gradation value to a shade (gray scale) or a hue around the pixel 1001 corresponding to (x', y'). Furthermore, if an overlap occurs in the paint pattern due to a subsequent paint line, the sum of the thickness values ​​of the overlapping parts in each paint line is calculated for the pixels in the overlapping parts, and the pixel value is updated to reflect the calculation result. Note that various instructions to the operator, such as an instruction to repaint a specific part or instructions regarding the attitude or speed of the paint gun 100 (the gun is tilted too much, the speed is too fast), may also be displayed in the image display of the thickness distribution 800 shown in FIG. 13.

[0080] Next, the flow of processing when implementing the present invention will be described with reference to FIG. First, as a step prior to the painting work, the paint operator inputs information on the type of vehicle to be painted, paint and paint gun conditions, and film thickness distribution image display conditions (paint area range dimensions, number of pixels) into an input screen (not shown) output to the display device of the paint work management device 10, and loads the 3D model data of the object to be painted into the device (step 220).

[0081] Next, the positions of the multiple markers attached to each characteristic point on the surface of the object to be coated are detected by the position detection sensor 121 of the measurement unit 120, and the coordinate values ​​(x, m, k ,ym k ,zm k ); (0≦k≦n) is calculated, and the calculated coordinates and the coordinate values ​​(xd k ,yd k ,zd k ); (0≦k≦n), the shape data position adjustment section 132 of the painting operation management unit 130 aligns the 3D model data with the position of the object to be painted in the measurement coordinate system of the measurement unit 120 (step 221).

[0082] Next, the painting work management device searches the painting condition management table 160 held by the device, and selects a model parameter set that matches the paint and painting gun condition information entered in step 220, as well as values ​​in the appropriate ranges for the painting gun operation and the paint film thickness distribution (step 222).

[0083] When step 222 is completed and the actual painting operation begins, the operation of the paint gun during the operation and the film thickness distribution are determined (step 230). The detailed procedure of this step 230 is shown in the flow chart of Fig. 15. In Fig. 15, the paint operation management device detects optical signals from each marker on the paint gun at each time during painting using the position detection sensor 121 of the measurement unit 120 (step 231).

[0084] Next, the marker analysis section 122 of the measurement unit 120 calculates the three-dimensional position coordinates (x, y, z) of the paint gun tip 105 in the painting work space and the direction vector (a, b, c) of the paint gun tip 105 at each instant based on the optical signals from each detected marker (step 232).

[0085] Furthermore, using the position coordinates (x, y, z) of the paint gun tip 105 and the direction vector (a, b, c) of the paint gun tip 105 calculated in step 232, a search is made for the paint center on the surface of the 3D model aligned with the position of the object to be painted in step 222, and the paint center coordinates (x', y', z') and the normal vector (α, β, γ) at the paint center 107a are identified (step 233).

[0086] Additionally, the painting work management device detects the paint supply flow rate by a paint flow meter (not shown) of the paint supplier 110 (step 234).

[0087] Next, the paint work management device uses the paint gun operation calculation section 133 of the paint work management unit 130 to calculate the distance l of the paint gun tip 105 from the painting center 107a of the surface to be painted, the inclination angle (horizontal angle φ, vertical angle θ) of the paint gun tip 105 to the painting center 107a of the surface to be painted, the movement speed v of the paint gun tip 105, the horizontality of the trajectory of the paint gun 100, and the spacing of the trajectory of the paint gun 100 from the (x, y, z) and (a, b, c) calculated in step 232 and the normal vector (α, β, γ) at the painting center 107a coordinates (x', y', z') (step 235).

[0088] Next, the paint work management device uses the coordinates (x', y', z') of the painting center 107a of the surface to be painted calculated in step 233 and the vertical inclination angle of the paint gun tip 105 relative to the painting center 107a of the surface to be painted calculated in step 235 to identify the paint pattern width region of the surface to be painted in the 3D model data using the surface shape analysis section 134 of the paint work management unit 130, and performs a shape analysis of the paint pattern width region (analysis of the inclination angle in each local area in the width direction of the paint pattern) (step 237).

[0089] Next, the film thickness calculation section 135 of the painting operation management unit 130 calculates the film thickness distribution in the pattern width direction formed around the coordinates (x', y') on the surface to be painted in the paint gun tip direction vector direction by substituting the model parameter set selected in step 222, the distance of the paint gun 100 from the painting center position of the surface to be painted, the moving speed of the paint gun 100, and the tilt angle of the paint gun 100 with respect to each local area position of the surface to be painted analyzed in step 237, into equation (7) of the film thickness distribution pattern model held by the painting operation management device. The painting status / operation instruction section 137 of the painting operation management unit 130 displays the film thickness distribution image based on the film thickness distribution image display conditions (painted area dimensions, number of pixels) input in step 220 (step 238).

[0090] In parallel with the processing of step 238, the painting condition analysis section 136 of the painting work management unit 130 compares the paint gun operation relating to the distance of the paint gun tip 105 from the surface to be painted, the tilt angle of the paint gun tip 105 from the painting center 107a of the surface to be painted, the movement speed of the paint gun tip 105, the horizontality of the paint gun 100 trajectory, and the spacing of the paint gun 100 trajectory, all calculated in step 235, with the values ​​of the appropriate range of paint gun operation selected in step 222, and determines whether the values ​​of the paint gun operation calculated in step 235 are within the appropriate range (step 236).

[0091] In parallel with the processing of step 236, the coating condition analysis section 136 of the coating operation management unit 130 compares the film thickness distribution value calculated in step 238 with the appropriate range of film thickness distribution values ​​selected in step 222 (see FIG. 14) and determines whether the film thickness distribution value calculated in step 238 is within the appropriate range (step 239).

[0092] Based on the results of the paint gun operation status analysis in step 236 and the results of the film thickness distribution status analysis in step 239, if the paint gun operation or film thickness distribution status is outside the appropriate range selected in step 222, the paint status / work instruction section 137 of the paint work management unit 130 issues a warning to the operator by outputting and displaying on the HMD 147 (see Figure 3) or by emitting an alert sound (step 240).

[0093] When the series of processes from step 231 to step 240 is completed, the process returns to Fig. 14 and proceeds to step 224. Step 230 is repeated until the painting work is completed, and after the painting work is completed, the process proceeds to step 224.

[0094] The painting condition analysis section 136 of the painting operation management unit 130 creates a histogram of each pixel value in the film thickness distribution image of the entire painted area range obtained in step 238, and identifies the location of the painting correction area and the content of the painting correction by analyzing the histogram (step 224).

[0095] Next, the painting status / work instruction section 137 of the painting work management unit 130 displays the position information of the correction area identified in step 236 and the correction content on the screen of the HMD 147 or the output device 149, thereby instructing the information to the worker (step 225).

[0096] The above series of processes improves the quality of painting by making the paint film thickness uniform in manual painting by workers, and also ensures protection and aesthetics by ensuring an appropriate film thickness. It also makes it possible to reduce the use of paint, which contributes to reducing painting costs and reducing emissions of volatile organic compounds. In this embodiment, an example in which the painting work management device according to the present invention is applied to manual painting has been shown, but it goes without saying that the present invention is not limited to manual painting and can also be applied to the verification of film thickness distribution when applied to robotic painting.

[0097] The program of the present invention causes an information processing device having a CPU to execute the coating operation management method shown in Figures 14 and 15. That is, the program causes a computer to execute a coating operation management method for managing a coating operation in which a coating is performed by spraying paint on an object to be coated with a paint gun, and executes the following steps: identifying the position of the coating surface of the object to be coated and aligning the 3D model data of the object to the position of the coating surface; identifying the distance of the paint gun 100 from the coating surface of the shape data of the object to be coated, the tilt angle of the shape data of the object to the coating surface, and the movement speed of the paint gun 100 from the position and attitude of the shape data of the object to be coated measured by the measurement unit; and calculating the film thickness distribution formed on the coating surface of the object to be coated based on information on the distance of the paint gun 100 from the coating surface of the shape data of the object to be coated, the tilt angle of the shape data of the object to the coating surface, and the movement speed of the paint gun 100, and information on a model formula that represents a film thickness distribution pattern according to the shape of the object to be coated in the shape data of the object to be coated. Furthermore, the program is for executing a step of determining whether the operation state of the paint gun is within an appropriate range based on at least one of the distance of the paint gun 100 from the painted surface of the shape data of the workpiece, or the inclination angle of the paint gun 100 from the painted surface of the shape data of the workpiece, the movement speed of the paint gun 100, the horizontality of the trajectory of the paint gun 100, and the spacing of the trajectory of the paint gun 100, and / or whether the film thickness distribution state is within an appropriate range based on the film thickness distribution formed on the painted surface of the workpiece, and a step of instructing the operator during painting work of the result of the determination.

[0098] It should be noted that the present invention is not limited to the above-mentioned embodiment, but includes various modified examples. For example, the above-mentioned embodiment has been described in detail to explain the present invention in an easily understandable manner, and the present invention is not necessarily limited to the embodiment having all of the described configurations. [Explanation of symbols]

[0099] 10 Painting work management device 20. Railroad cars 22 Surface to be painted 30, 30a to 30f markers 40 Mounting frame 100 Paint Gun 101 Handle 102 Trigger lever 105 Paint gun tip 106 Hose 107 Paint Pattern 107a Painting Center 110 Paint supply machine 120 Measurement Unit 121, 121a to 121j position detection sensor 122 Marker Analysis Unit 130 Painting Work Management Unit 131 Data storage unit 132 Shape data position adjustment unit 133 Paint gun operation calculation unit 134 Painted surface shape analysis department 135 Film thickness calculation section 136 Painting Condition Analysis Department 137 Painting condition / work instruction section 140 PC 141 CPU 142 Main storage 143 Auxiliary memory I / F 144 Network Interface 145 Input / Output Interface 146 Router / Hub 147 HMD 148 Input Devices 149 Output Device 150 Auxiliary storage 151 Shape data position adjustment program 152 Paint gun operation calculation program 153 Painted surface shape analysis program 154 Film Thickness Calculation Program 155 Paint condition analysis program 160 Painting condition management table 170 Painted object shape data 300 3D position coordinate data string of the tip of the paint gun 400~402 Paint thickness pattern 403 Pattern width 500 Paint gun tip trajectory 501 Data string of coordinates on the surface to be painted in the direction of the paint gun tip vector 502 Fitting straight line in painting line 503 Horizontality of the paint gun trajectory (ψ) 504 Fitting line at previous paint line 505 Paint gun orbit interval (paint interval) 700 Normal vector of the surface to be painted 701 Paint thickness pattern on a flat painted surface 702 Film thickness distribution in the pattern width direction on a flat coated surface 703 Inclination angle of the normal vector of the surface to be painted with respect to the direction vector of the tip of the paint gun 704 Painting Pattern on Curved Surface 705 Film Thickness Distribution in the Pattern Width Direction on Curved Coating Surface 800 Film thickness distribution in the pattern width direction under standard coating conditions 801 Each local area within the pattern width of the coating surface 802 Injection paint 1000 Painted area range on the surface to be painted 1001 Pixels corresponding to the tip direction of the paint gun in the film thickness distribution image 1002 Film thickness distribution in the pattern width direction

Claims

1. A coating operation management device that manages a coating operation in which paint is sprayed onto an object to be coated by a coating gun, a measurement unit that measures the position and orientation of the paint gun relative to the surface of the object to be painted; a coating operation management unit for calculating a film thickness formed on the object by spraying the paint, The painting operation management unit includes: Holding shape data of the object to be coated; Identifying the distance of the paint gun relative to the surface to be painted of the shape data of the object to be painted, the inclination angle of the paint gun relative to the surface to be painted of the shape data of the object to be painted, and the moving speed of the paint gun; A painting work management device characterized in that the painting work management unit calculates the film thickness distribution formed on the painted surface of the workpiece based on information regarding the distance, the tilt angle, and the moving speed of the paint gun, and information regarding a model equation that represents a film thickness distribution pattern corresponding to shape data of the workpiece.

2. 2. The painting operation management system according to claim 1, The shape of the surface to be coated in the shape data of the object to be coated is represented by normal vectors of each local region constituting the surface to be coated, the tilt angle of the paint gun is indicated by a tip direction vector of the paint gun, The coating operation management device is characterized in that the coating operation management unit calculates the film thickness distribution using the normal vector and the tip direction vector.

3. 3. The painting operation management system according to claim 2, The painting operation management unit includes: A painting work management device characterized by identifying the position of the workpiece in the measurement coordinate system of the measurement unit, aligning shape data of the workpiece to the identified position of the workpiece, and calculating the distance of the tip of the paint gun from the shape data of the workpiece to the surface to be painted, or the inclination angle of the data of the workpiece to the surface to be painted.

4. 3. The painting operation management system according to claim 2, The painting operation management unit includes: A parameter expressing a change in the film thickness distribution pattern due to a change in the tilt angle is stored in advance as a model formula; Detecting an inclination angle of each local area of ​​the object to a tip direction of the paint gun from a normal vector of each local area of ​​the object; A coating operation management device that calculates a coating thickness distribution in the local area using the detected tilt angle and the model formula.

5. The painting operation management device according to any one of claims 1 to 4, A display device is provided that can be checked by the worker during painting work, The painting work management device is characterized in that the painting work management unit identifies areas on the surface of the workpiece where paint is excessive or insufficient based on the calculated film thickness distribution and displays the areas on the display device.

6. A program for causing a computer to execute a painting operation management method for managing a painting operation in which paint is manually sprayed onto an object to be painted by a paint gun, comprising: determining a distance of the paint gun relative to the surface of the workpiece from the shape data of the workpiece, an inclination angle of the shape data of the workpiece relative to the surface of the workpiece, and a moving speed of the paint gun from the position and attitude of the paint gun measured by a measurement unit that measures the position and attitude of the paint gun relative to the surface of the workpiece; calculating a film thickness distribution formed on the surface of the object to be coated based on information regarding the distance, the inclination angle, and the moving speed of the paint gun, and information regarding a model formula that represents a film thickness distribution pattern corresponding to the shape of the surface to be coated in the shape data of the object to be coated; determining whether the operation state of the coating gun is within an appropriate range and / or whether the state of the coating thickness distribution is within an appropriate range; displaying the result of the judgment on a display device that can be visually confirmed by an operator during painting work; A program for executing.

7. The program according to claim 6, The program, characterized in that the determining step is based on at least one of the distance of the paint gun, the tilt angle, the moving speed, the horizontality of the paint gun trajectory, and the spacing of the paint gun trajectory.

8. The program according to claim 7, The display step is characterized in that the program identifies and displays areas on the surface of the workpiece where there is an excess or deficiency of paint based on the calculated film thickness distribution.

9. The program according to claim 8, further comprising: A program characterized by representing the shape of the surface to be coated of the object to be coated by the normal vector of each local area that constitutes the surface to be coated, representing the inclination angle of the paint gun by the tip direction vector of the paint gun, and calculating a film thickness distribution pattern using the amount of change in the angle between the normal vector and the tip direction vector.

10. A railway vehicle is painted by spraying paint onto an object to be painted with a paint gun using a paint work management device including a measurement unit that measures the position and attitude of a paint gun relative to a surface of the object to be painted, and a paint work management unit that calculates a film thickness formed on the object by spraying paint, The measuring unit is measuring the position and attitude of the paint gun; A step of reading 3D shape data of the object to be painted; determining a distance of the 3D shape data of the paint gun relative to the surface to be painted, an inclination angle of the 3D shape data relative to the surface to be painted, and a moving speed of the paint gun from the position and attitude of the paint gun measured by the measurement unit; calculating a film thickness distribution formed on the surface of the object to be coated based on information regarding the distance, the inclination angle, and the moving speed of the paint gun, and information regarding a model equation that represents a film thickness distribution pattern corresponding to the shape of the surface to be coated in the shape data of the object to be coated; A railway vehicle, characterized in that the coating is performed while repeating a step of judging whether the film thickness distribution formed on the surface to be coated is appropriate or not and displaying the result to an operator using a display device.

11. The railway vehicle according to claim 10, The shape of the surface to be coated in the 3D shape data is represented by normal vectors of each local area constituting the surface to be coated, a coating thickness distribution pattern is calculated using an amount of change in an angle between the normal vector and the tip direction vector, wherein the calculating step indicates the inclination angle of the coating gun by a tip direction vector of the coating gun, and a coating thickness distribution pattern is calculated using an amount of change in an angle between the normal vector and the tip direction vector.

12. The railway vehicle according to claim 10, A railway vehicle characterized in that, in a step of determining whether the film thickness distribution formed on the surface to be painted is appropriate, areas on the surface of the object to be painted where there is an excess or deficiency of paint are identified, and the worker is prompted to apply additional paint.

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