Spraying parameter setting method, spraying method and spraying system

Abstract

To provide a spraying parameter setting method, a spraying method and a spraying system which can easily achieve automatic spraying work while avoiding a predetermined site such as a sleeve.SOLUTION: A spraying parameter setting method comprises: a step in which at least one non-target region S constituted of circular opening parts which are not sprayed is set in a body to be sprayed and a distance sensor scans the body to be sprayed in a length direction thereof to measure a distance from a position at an interval in a width direction orthogonal to the length direction of the body to be sprayed up to a surface of the body to be sprayed, so that at least four positions at an outer edge of at least one non-target region S are detected on the basis of the measured result of the distance; and a step in which a diameter or a radius of the circle of the non-target region S and a position of the region in the body to be sprayed are calculated on the basis of the detected positions of the four points and a spraying parameter is set on the basis of the calculated results.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a spraying parameter setting method, a spraying method, and a spraying system for spraying a fire-resistant coating material onto steel members such as beams and columns of a building. [Background technology]

[0002] Conventionally, there is known a method of spraying a fireproof coating material onto steel members such as beams and columns of a building (see, for example, Patent Document 1). The spraying method of Patent Document 1 involves placing a spraying device at a position and height a predetermined distance away from the member to be sprayed, inputting information indicating the cross-sectional shape of the member to be sprayed, information indicating the position of the member to be sprayed from a reference position, information indicating the positional relationship between the spraying device and the member to be sprayed, information indicating the spraying range on the member to be sprayed, and information indicating the spraying order, generating control information for controlling the spraying device, and then controlling the spraying operation of the spraying device based on this control information, and spraying the fireproof coating material onto the member to be sprayed from the nozzle of the spraying device. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2022-174494 A Summary of the Invention [Problem to be solved by the invention]

[0004] When spraying a beam web surface having a sleeve (opening) fully automatically using the spraying method of Patent Document 1, if the nozzle is simply moved along a rectangular wave-like trajectory along the beam web surface while spraying the fireproof coating material, the material sprayed at the position of the sleeve on the beam web surface is wasted. For this reason, there was a demand for a technology that can realize an automatic spraying operation that avoids the sleeve.

[0005] However, to achieve automatic spraying work that avoids sleeves, it is necessary to refer to drawings and set values ​​related to the shape and position of the sleeves within the spraying range (for example, the number of sleeves, sleeve core height, sleeve pitch, sleeve diameter, etc.), which takes a considerable amount of time and effort. For this reason, a simple technology that does not require time and effort is required.

[0006] The present invention has been made in consideration of the above, and aims to provide a spraying parameter setting method, a spraying method, and a spraying system that can easily realize automatic spraying work while avoiding specified areas such as sleeves. [Means for solving the problem]

[0007] In order to solve the above-mentioned problems and achieve the object, the spray parameter setting method of the present invention is a method for setting spray parameters that stipulate the operation of the spray nozzle relative to the body to be sprayed when spraying the spray material ejected from the spray nozzle onto the body to be sprayed, and is characterized in that the body to be sprayed has at least one non-target area consisting of a circular opening that is not the target of spraying, and a distance sensor is used to scan the length of the body to measure the distance from positions spaced apart in the width direction perpendicular to the length of the body to the surface of the body to be sprayed, and based on this measurement result, the positions of at least four points on the outer edge of at least one non-target area are detected, and based on the detected positions of the four points, the diameter or radius of the circle of the non-target area and its position on the body to be sprayed are calculated, and the spray parameters are set based on this calculation result.

[0008] In addition, the spraying method of the present invention is a method of spraying a spray material ejected from a spray nozzle onto a target body, and is characterized in that spray parameters are set by the above-mentioned spray parameter setting method, and the spray nozzle is operated based on the set spray parameters, thereby spraying the spray material onto the target body while avoiding non-target areas.

[0009] In addition, the spraying system of the present invention is a system for spraying a spray material ejected from a spray nozzle onto a target body, and is characterized in that it comprises a parameter setting means for setting spray parameters using the above-mentioned spray parameter setting method, and a control means for operating the spray nozzle based on the set spray parameters, thereby spraying the spray material onto the target body while avoiding non-target areas. Effect of the Invention

[0010] According to the spray parameter setting method of the present invention, a method for setting spray parameters that stipulate the operation of the spray nozzle with respect to a body to be sprayed when spraying the spray material emitted from the spray nozzle onto the body to be sprayed includes the steps of: providing at least one or more non-target areas consisting of circular openings that are not to be sprayed on the body to be sprayed; scanning the body to measure the distances from positions spaced apart in the width direction perpendicular to the length direction of the body to be sprayed to the surface of the body to be sprayed by a distance sensor in the length direction of the body to be sprayed, detecting at least four positions on the outer edge of at least one non-target area based on the measurement results; calculating the diameter or radius of the circle of the non-target area and its position on the body to be sprayed based on the detected positions of the four points, and setting the spray parameters based on the calculation results; thus, the shape and position of the non-target area such as a sleeve can be identified by scanning using a distance sensor without referring to a drawing, etc., and it does not take time or effort. Therefore, it is possible to easily realize an automatic spraying operation that avoids a specified part such as a sleeve.

[0011] In addition, according to the spraying method of the present invention, a method is provided for spraying a spray material ejected from a spray nozzle onto a target body, in which spray parameters are set by the above-mentioned spray parameter setting method, and the spray nozzle is operated based on the set spray parameters, thereby spraying the spray material onto the target body while avoiding non-target areas, thereby achieving the effect of easily realizing automatic spraying work while avoiding specified areas such as sleeves.

[0012] In addition, according to the spraying system of the present invention, the system sprays the spray material ejected from the spray nozzle onto the object to be sprayed, and is equipped with a parameter setting means for setting spray parameters using the above-mentioned spray parameter setting method, and a control means for operating the spray nozzle based on the set spray parameters, thereby spraying the spray material onto the object to be sprayed while avoiding non-target areas, thereby achieving the effect of easily realizing automatic spraying work while avoiding specified areas such as sleeves. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is an explanatory diagram of an embodiment of the spraying parameter setting method, spraying method and spraying system of the present invention, where (1) is a side view showing the positional relationship between the spraying surface and the spraying nozzle, (2) is a schematic oblique view, and (3) is a front view of the beam web surface. [Diagram 2] FIG. 2 shows an example of a moving path of the spray nozzle, where (1) is a front view and (2) is a side view. [Diagram 3] FIG. 3 is an explanatory diagram of an embodiment of the spray parameter setting method according to the present invention. [Figure 4] FIG. 4 is an explanatory diagram of an embodiment of the spray parameter setting method according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of a spray parameter setting method, a spray method, and a spray system according to the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to these preferred embodiments.

[0015] As shown in FIG. 1(1), a spraying system 10 according to an embodiment of the present invention sprays a fireproof coating material 20 (spraying material) such as sprayed rock wool from a spray nozzle 14 provided in a spraying device 12 onto a spraying surface 18 of a steel beam 16 (a body to be sprayed) while avoiding a sleeve S (a non-target area). In this embodiment, the steel beam 16 is an H-shaped steel with an H-shaped cross section, but the present invention is not limited to this. Also, as shown in FIG. 1(3), a case is described in which a plurality of sleeves S consisting of circular openings that are not the target of spraying are arranged at intervals in the beam axis direction (horizontal direction) on the web surface of the steel beam 16, but the present invention is not limited to this, and there may be at least one sleeve S. Also, the beam axis direction (length direction in the present invention) is the x-axis direction, the height direction (width direction in the present invention) perpendicular to the x-axis is the y-axis direction, and the horizontal direction perpendicular to the x-axis is the z-axis direction.

[0016] The spraying device 12 includes a manipulator mounted on a cart (not shown), a control unit 22 for controlling its own operation, and a setting unit 24 for setting and inputting parameter data. The cart is movably disposed on the floor near the steel beams 16, and the manipulator has a plurality of motion joints, an arm, and an actuator for driving them, and is provided so as to be movable up and down, forward and backward, and left and right relative to the cart. The arm can take any posture. As shown in FIG. 1 (2), the spraying nozzle 14 is provided at the tip of the arm so as to be able to swing. A distance sensor 26, an angle sensor (not shown), and a speed sensor are provided near the spraying nozzle 14. For example, a device described in Patent Document 1 can be used as the spraying device 12.

[0017] The distance sensor 26 is a sensor that measures the distance between the spray nozzle 14 and the spray surface 18, and is arranged in a pair on either side of the nozzle axis of the spray nozzle 14. The distance sensor 26 can be a non-contact sensor such as a laser range finder using laser light. When a laser range finder is used, the laser range finder irradiates a laser beam forward and receives the laser beam reflected by the spray surface 18 to measure the distance to the spray surface 18. The angle sensor is a sensor that detects the nozzle angle of the spray nozzle 14 with respect to a reference direction (for example, the horizontal direction), and can be configured, for example, by a gyro sensor. The speed sensor is a sensor that detects the speed at which the spray nozzle 14 moves, and can be configured, for example, by a three-axis acceleration sensor. This speed sensor can detect the speed by performing a calculation based on the detected acceleration.

[0018] The control unit 22 is a control means for controlling the operation of the manipulator based on detection signals from the distance sensor 26, angle sensor, speed sensor, etc., and parameter data set by the setting unit 24, and is disposed, for example, on the carriage of the spraying device 12. This control unit 22 generates control data from the parameter data, and controls the operation of the manipulator using the detection signals and control data from each sensor. Through this operation control, the position, orientation, movement path, movement speed, and spray timing of the fireproof coating material 20 of the spray nozzle 14 are manipulated, and the fireproof coating material 20 is sprayed from the spray nozzle 14 onto the spray surface 18 while avoiding the sleeve S.

[0019] The setting unit 24 is a parameter setting means for setting and inputting parameter data, and is disposed, for example, on the dolly of the spraying device 12. The setting unit 24 can be composed, for example, of a setting input field in a table format displayed on the screen of a computer or the like, and a keyboard, mouse, and the like (not shown) for inputting setting values ​​into the setting input field. The parameter data includes beam information parameter items and spraying parameter (operation parameter) items.

[0020] The beam information parameter items, as shown in FIG. 1(1), include shape parameter items related to the surface shape of the steel beam 16, such as beam depth, flange width, flange thickness, beam top height from the floor to the top of the beam, and spray range in the beam axis direction, and are set to generate the trajectory of the spray nozzle 14.

[0021] The spray parameter items consist of basic setting items, path setting items related to paths (movement paths), and sleeve setting items related to the spray operation around the sleeve S. The basic setting items include operation parameter items such as the angle (direction) of the spray nozzle 14 relative to the web surface, the distance (position) of the spray nozzle 14 relative to the web surface, the movement speed, acceleration, and deceleration of the spray nozzle 14. The path setting items are setting items related to paths when the spray nozzle 14 is moved along the web surface in a rectangular wave-like (zigzag) trajectory, as shown in Figures 2(1) and (2). Each path extends in the y-axis direction, and paths are spaced apart in the x-axis direction. The path setting items include operation parameter items such as the position and start point (node) of the first path, pitch e which is the distance in the x-axis direction between adjacent paths, number of paths f which is the number of paths, path length g, and accuracy i which is related to smoothness near the path turnaround point.

[0022] In this embodiment, as shown in FIG. 2(2), it is assumed that in each pass, the spray nozzle 14 moves in the y-axis direction on the web surface from node 1 to node 4, starting from node 0 on the upper surface of the lower flange. When setting the operation (angle, etc.) of the spray nozzle 14 to change at each of nodes 0 to 4, it is desirable to prevent the nodes from being located within the range of the sleeve S. In this case, for example, the distance h1 from the upper surface of the lower flange to node 2 may be set to be smaller than the distance H1 from the upper surface of the lower flange to the lower end of the sleeve S. Furthermore, the distance h3 from the lower surface of the upper flange to node 3 may be set to be smaller than the distance H3 from the lower surface of the upper flange to the upper end of the sleeve S.

[0023] The sleeve setting items include the number of sleeves, sleeve pitch, sleeve core height (position on the body being sprayed), sleeve diameter, folding standard, folding margin, sleeve escape amount, the speed at which the spray nozzle 14 sprays around the sleeve S, the crossing speed when crossing the center of the sleeve S in the x-axis direction, the spray angle when spraying around the sleeve S, and the number of times the sleeve S is sprayed.

[0024] The number of sleeves, the sleeve pitch, the sleeve core height, and the sleeve diameter are calculated by the spray parameter setting method according to the embodiment of the present invention. Next, the calculation procedure will be described.

[0025] As shown in FIG. 3, first, the distance sensor 26 scans and measures the distance in the z-axis direction from positions (measurement heights L1, L2 from a predetermined reference line) spaced apart in the y-axis direction to the web surface (spray surface 18) in the x-axis direction. In this case, for example, the measurement is performed while moving the spray nozzle 14 in the scanning direction. The measurement heights L1, L2 are arbitrary, but must be set to a height at which the sleeve S is present on the scanning path. The example in the figure shows a case in which three sleeves S with different center positions and diameters are arranged on the web surface at intervals in the x-axis direction. In this example, the scan starts from the start P1 at the left end at the measurement height L1 toward the right, scans over the three sleeves S, then scans from the right end at the measurement height L2, scans over the three sleeves S, and ends at the end P2 at the left end. It is preferable to use a laser range finder for the distance sensor 26. However, the present invention is not limited to a laser range finder, and any distance measuring means based on another measurement principle may be used as long as it can detect the position of the outer edge of the sleeve S.

[0026] This scanning detects position Q where the measured distance value changes suddenly. This position Q is a position on the circumference that forms the outer edge of the sleeve S, and is detected four times for each sleeve S. The detected position is recorded in a memory or the like as coordinates (x, y) in an xy Cartesian coordinate system.

[0027] Next, values ​​relating to the shape and position of the sleeve S are calculated based on the coordinates of the detected position. If the total number of detections is M, the number of sleeves can be calculated using the following formula. (Number of sleeves)=M / 4

[0028] FIG. 4 shows an example of coordinates detected for one sleeve S. The coordinates (x, y) on the circumference of the sleeve S can be calculated using the following formula. Here, r is the radius of the sleeve S, X is the x coordinate of the center of the circle, and Y is the y coordinate of the center of the circle. x1 to x3 and y1 to y3 are the detected x and y coordinates. L is the difference between the measured heights L1 and L2. (xX) 2 +(yY) 2 =r 2 (Equation that represents the circle of sleeve S) X=(x1+x2) / 2 Y=y2+(x2-x3)(x3-x1) / 2L-L / 2 r 2 =(x2-x1) 2 / 4+{L / 2-(x2-x3)(x3-x1) / 2L} 2 L=L1-L2

[0029] The sleeve pitch, sleeve core height, and sleeve diameter can be calculated from the center coordinates (X, Y) and radius r of the sleeve S calculated from the above formula. Based on the calculation results, the sleeve setting items (spray parameters) can be set.

[0030] The operation and function of the above configuration will now be described. First, the spraying device 12 is placed on the floor near the steel beams 16. Next, the setting unit 24 is used to input beam information parameter items related to the steel beams 16 and spraying parameter items to set the parameter data. Of the spraying parameters, the number of sleeves, sleeve pitch, sleeve core height, and sleeve diameter are calculated by the spraying parameter setting method described above. This makes it possible to easily set the movement path of the spraying nozzle 14 for automatic spraying work.

[0031] When the parameter data is set, the control unit 22 generates control data and controls the operation of the manipulator of the spraying device 12 based on the detection signals of each sensor and the control data. As a result, the spray nozzle 14 is positioned at a preset start position from the spraying surface 18 of the steel beam 16. The start position can be set, for example, to the lower left side of the web surface as shown in FIG. 2(1). After adjusting the nozzle angle and distance to the spraying surface 18, the spraying operation is started by spraying the fireproof coating material from the spray nozzle 14, and the spray nozzle 14 is moved in a rectangular wave shape along the set path. The spraying operation around the sleeve S is performed taking into account the sleeve setting items and the like.

[0032] According to the above method, by setting the parameter values ​​in advance, it is possible to realize automatic spraying operation on the web surface while avoiding the sleeve S, even depending on differences in the cross-sectional shape of the beam, the height position of the beam, the position and shape of the sleeve S, the spray thickness, and the properties of the spray material.

[0033] In particular, according to this embodiment, the shape and position of the sleeve S can be easily specified without referring to drawings or the like, which saves time and effort. Therefore, automatic spraying work can be easily achieved while avoiding the sleeve S. This makes it possible to improve productivity by reducing the labor required.

[0034] As described above, the spray parameter setting method according to the present invention is a method for setting spray parameters that stipulate the operation of the spray nozzle with respect to the object to be sprayed when the spray material ejected from the spray nozzle is sprayed onto the object to be sprayed, and includes the steps of: providing at least one or more non-target areas consisting of circular openings that are not to be sprayed on the object to be sprayed; scanning the object to be sprayed with a distance sensor in the longitudinal direction to measure the distances from positions spaced apart in the width direction perpendicular to the longitudinal direction of the object to the surface of the object to be sprayed; detecting at least four positions on the outer edge of at least one non-target area based on the measurement results; and calculating the diameter or radius of the circle of the non-target area and its position on the object to be sprayed based on the detected positions of the four points; and setting the spray parameters based on the calculation results. Therefore, the shape and position of the non-target area such as a sleeve can be identified by scanning using a distance sensor without referring to a drawing, and it does not take time or effort. Therefore, automatic spraying work that avoids a specified part such as a sleeve can be easily realized.

[0035] In addition, according to the spraying method of the present invention, a method is provided in which a spray material ejected from a spray nozzle is sprayed onto a target body, in which spray parameters are set by the above-mentioned spray parameter setting method, and the spray nozzle is operated based on the set spray parameters, so that the spray material is sprayed onto the target body while avoiding non-target areas, thereby easily achieving automatic spraying work that avoids specified areas such as sleeves.

[0036] In addition, according to the spraying system of the present invention, the system sprays the spray material ejected from the spray nozzle onto the object to be sprayed, and is equipped with a parameter setting means for setting spray parameters using the above-mentioned spray parameter setting method, and a control means for operating the spray nozzle based on the set spray parameters, thereby spraying the spray material onto the object to be sprayed while avoiding non-target areas, thereby easily realizing automatic spraying work while avoiding specified areas such as sleeves.

[0037] The "Sustainable Development Goals (SDGs)" are 17 international goals that were adopted at the United Nations Summit in September 2015. The spraying parameter setting method, spraying method, and spraying system according to the present embodiment can contribute to the achievement of, for example, goal 8. "Decent work and economic growth" out of the 17 SDGs. [Industrial Applicability]

[0038] As described above, the spraying parameter setting method, spraying method and spraying system of the present invention are useful for spraying fire-resistant coating material onto steel components such as beams and columns of a building, and are particularly suitable for easily realizing automatic spraying work while avoiding specified areas such as sleeves. [Explanation of symbols]

[0039] 10 Spraying System 12 Spraying equipment 14 Spray nozzle 16 Steel beam (body to be sprayed) 18 Sprayed surface 20 Fireproof coating material (sprayed material) 22 Control section (control means) 24 Setting section (parameter setting means) 26 Distance Sensor S Sleeve (non-target area)

Claims

1. 1. A method for setting spray parameters that govern the operation of a spray nozzle relative to a target body when spraying a spray material emitted from the spray nozzle onto the target body, comprising: The object to be sprayed is provided with at least one non-target area consisting of a circular opening that is not the target of spraying, A step of measuring the distance from positions spaced apart in a width direction perpendicular to the length direction of the body to the surface of the body by scanning in the length direction of the body to be sprayed using a distance sensor, and detecting the positions of at least four points on the outer edge of at least one non-target area based on the measurement results; A spraying parameter setting method characterized by comprising a step of calculating the diameter or radius of the circle of the non-target area and its position on the body to be sprayed based on the positions of the four detected points, and setting spraying parameters based on the calculation results.

2. A method for spraying a spray material ejected from a spray nozzle onto a target body, comprising the steps of: A spraying method characterized by setting spraying parameters using the spraying parameter setting method described in claim 1, and operating the spray nozzle based on the set spraying parameters, thereby spraying the spray material onto the object to be sprayed while avoiding non-target areas.

3. A system for spraying a spray material ejected from a spray nozzle onto a target body, comprising: A spraying system comprising: a parameter setting means for setting spraying parameters using the spraying parameter setting method described in claim 1; and a control means for operating the spray nozzle based on the set spraying parameters to spray the spray material onto the object to be sprayed while avoiding non-target areas.

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