Painting system

Abstract

This invention provides a painting system that can improve painting quality even when vibrations or other fluctuations occur in the image acquisition means. [Solution] The painting system 1 comprises a painting head unit 50 equipped with a painting head 53, a robot arm R1 that moves the painting head unit 50 to a desired position, an image acquisition means for acquiring painting data of the painting area, and a control unit that controls the operation of a 3D scanner 140 and also controls the operation of the painting head 53 and the robot arm R1. The control unit operates the image acquisition means to scan a measurement image with the image acquisition means before painting is performed to acquire measurement image data that reflects the vibration state of the image acquisition means, and based on the measurement image data acquired by the image acquisition means, creates correction painting data to correct the misalignment of the droplet landing position, and performs drive control of the robot arm and painting head based on the correction painting data.

Description

Technical Field

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[0001] The present invention relates to a painting system.

Background Art

[0002] In the painting line of vehicles such as automobiles, robot painting using robots has become the mainstream. As an example of the configuration related to this robot painting, for example, Patent Document 1 discloses the following configuration. In the painting robot disclosed in this Patent Document 1, a technique for determining a discharge defect of a nozzle based on a test pattern having a plurality of check lines is disclosed.

Prior Art Documents

Patent Documents

[0003] <000001​​​​​​​​​​​​​​​​​​​​​​​​To solve the above problems, according to a first aspect of the present invention, a painting system is provided which includes a painting robot for painting parts of a vehicle, comprising: a painting head unit having a painting head having a plurality of nozzles for discharging droplets of paint; a robot arm having the painting head unit attached to its tip and moving the painting head unit to a desired position; an image acquisition means for acquiring painting data of the painted parts painted by the painting head; and a control unit for controlling the operation of the image acquisition means and controlling the operation of the painting head and the robot arm based on the image data transmitted from the image acquisition means, wherein the control unit operates the image acquisition means to scan a measurement image with the image acquisition means before painting is performed to acquire measurement image data that reflects the vibration state of the image acquisition means, creates corrective painting data to eliminate deviations in the landing position of droplets discharged from the painting head based on the measurement image data acquired by the image acquisition means, and performs drive control of the robot arm and the painting head based on the corrective painting data. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a painting system that can improve painting quality even if fluctuations such as vibrations occur in the image acquisition means. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic diagram showing the overall configuration of a painting robot according to one embodiment of the present invention. [Figure 2] This figure shows a schematic configuration of a painting system equipped with the painting robot shown in Figure 1. [Figure 3] This figure shows a front view of the nozzle-forming surface that dispenses paint, which is part of the painting head unit of the painting robot shown in Figure 1. [Figure 4] Figure 3 is a plan view showing the configuration of the nozzle forming surface in a painting head unit different from the painting head unit shown in Figure 3. [Figure 5]This diagram shows the control flow for the painting robot shown in Figure 1, when corrective painting data is created and painting is performed. [Figure 6] This figure shows an example of a measurement image scanned by the 3D scanner equipped on the painting robot shown in Figure 1. [Figure 7] This figure shows measurement image data obtained by scanning with a 3D scanner equipped on the painting robot shown in Figure 1. [Figure 8] This figure shows the correction paint data created based on the measurement image data shown in Figure 7. [Figure 9] Figure 1 shows the normal painting nozzle and correction nozzle in the painting head of the painting robot shown. [Modes for carrying out the invention]

[0009] Hereinafter, a painting system 1 and a painting robot 10 according to one embodiment of the present invention will be described with reference to the drawings. In the following description, the X direction will be the longitudinal direction of the nozzle forming surface 52 (painting head 53) as necessary, with X1 being the right side in Figure 3 and X2 being the left side in Figure 3. The Y direction will be the short direction (width direction) of the nozzle forming surface 52 (painting head 53), with Y1 being the upper side of the paper in Figure 3 and Y2 being the lower side of the paper in Figure 3.

[0010] (1. Overview of the painting robot 10) The painting robot 10 of this embodiment performs "painting" on objects to be painted, such as vehicles or vehicle parts (hereinafter, vehicle parts that are part of a vehicle will also be described as vehicles) located on a painting line in an automobile manufacturing plant. Its purpose is to form a paint film on the surface of the object to be painted, thereby protecting the surface and providing an aesthetic appearance. Therefore, it is necessary to paint vehicles moving along the painting line at predetermined intervals within a certain time frame to the desired painting quality.

[0011] Furthermore, the painting robot 10 of this embodiment is capable of not only forming the aforementioned paint film, but also forming various designs and images on objects to be painted, such as vehicles and vehicle parts. Note that the objects to be painted are not limited to vehicles and vehicle parts; they can be any other parts that require painting, such as exterior parts for airplanes and trains.

[0012] (1-1. Overall configuration of painting system 1 and painting robot 10) Figure 1 is a schematic diagram showing the overall configuration of a painting robot 10 according to one embodiment of the present invention. Figure 2 is a diagram showing the schematic configuration of a painting system 1 equipped with the painting robot 10 shown in Figure 1. As shown in Figure 2, the painting system 1 includes a painting robot 10 and an image processing device 200.

[0013] (1-2. Regarding painting robot 10) As shown in Figure 1, the painting robot 10 mainly consists of a robot body 20 and a painting head unit 50. The painting robot 10 shown in Figure 1 is an example of a 6-axis vertical articulated robot, but the painting robot 10 can be any type of robot, such as a vertical articulated robot other than a 6-axis robot, a horizontal articulated robot, or a Cartesian robot.

[0014] (1-3. Regarding the robot body 20) As shown in Figure 1, the robot body 20 mainly consists of a base 21, first to sixth rotation axes 22a to 22f, legs 23, first rotating arm 24, second rotating arm 25, rotating arm 26, wrist section 27, and motors M1 to M6 that drive these components. The section from the legs 23 to the wrist section 27 corresponds to the robot arm R1, but other parts such as the base 21 may also correspond to the robot arm R1.

[0015] Among these, the base 21 is a part installed at an installation site such as a floor surface, but the base 21 may be capable of traveling with respect to the installation site. Further, the leg portion 23 is a portion erected upward from the base 21, and is provided so as to be rotatable with respect to the base 21 via a first rotating shaft 22a by driving of a motor M1 (see FIG. 2). Note that the leg portion 23 may be configured not to rotate with respect to the base 21.

[0016] Further, at the upper end of the leg portion 23, a first swing arm 24 is provided so as to be swingable via a second rotating shaft 22b by driving of a motor M2. Further, at the tip end side of the first swing arm 24, a second swing arm 25 is provided so as to be swingable via a third rotating shaft 22c by driving of a motor M3.

[0017] Further, at the tip end side of the second swing arm 25, a rotating arm 26 is provided so as to be rotatable around the central axis of the second swing arm 25. This rotating arm 26 is rotatable via a fourth rotating shaft 22d by driving of a motor M4. Further, at the tip end side of the rotating arm 26, a wrist portion 27 is provided. This wrist portion 27 enables a rotational movement around, for example, a plurality of different-direction shaft portions such as two by driving of a motor M5 and a motor M6. In FIG. 1, the rotating shafts enabling the rotational movement are respectively a fifth rotating shaft 22e and a sixth rotating shaft 22f. Thereby, the orientation of the painting head unit 50 can be accurately controlled. Note that the number of the shaft portions may be any number as long as it is two or more.

[0018] Further, a painting head unit 50 is attached to the wrist portion 27, but this painting head unit 50 may be provided detachably with respect to the wrist portion 27.

[0019] (1-4. Regarding the paint supply unit 40) As shown in Figure 2, the painting system 1 and the painting robot 10 are provided with a paint supply unit 40. The paint supply unit 40 is the part that supplies paint to the painting head unit 50. For this purpose, the paint supply unit 40 includes a supply passage 41 for supplying paint from a paint storage unit (not shown), a pump (not shown), a valve (not shown), and a return passage 42 for recovering paint that was not discharged.

[0020] Furthermore, if the paint is supplied from outside the painting robot 10, the painting robot 10 does not need to have a paint storage section, and may have a paint storage section outside the painting robot 10.

[0021] (1-5. Regarding the Painting Head Unit 50) Next, the paint head unit 50 will be described. Figure 3 shows a front view of the nozzle-forming surface 52 of the paint head unit 50, which is used to discharge paint. As shown in Figure 3, the paint head unit 50 is equipped with a head cover (not shown), and various components, including the paint head 53, are built into the head cover. The paint head 53 is provided with numerous nozzles 54 for discharging paint.

[0022] As shown in Figure 3, the paint-discharging side (nozzle-forming surface 52) of the paint head 53 has the openings of multiple nozzles 54 exposed. In the following description, the openings of the nozzles 54 will also be referred to as nozzles 54.

[0023] Furthermore, the nozzle forming surface 52 is provided with multiple nozzle rows 55 in which the nozzles 54 are arranged in a direction inclined with respect to the longitudinal direction of the painting head unit 50. In this embodiment, the nozzle row 55 includes a first nozzle row 55A located on one side (Y2 side) of the main scanning direction (Y direction) and a second nozzle row 55B located on the other side (Y1 side) of the main scanning direction.

[0024] Furthermore, when dispensing paint, the driving timing of each nozzle 54 is controlled so that droplets dispensed from nozzles 54 in the second nozzle row 55B land between droplets dispensed from adjacent nozzles 54 in the first nozzle row 55A. This improves the dot density during painting.

[0025] Furthermore, in the configuration shown in Figure 3, the arrangement of nozzles 54 in the first nozzle row 55A and the arrangement of nozzles 54 in the second nozzle row 55B are inclined with respect to the short direction (Y direction; main scanning direction) of the paint head 53. However, it is not necessary to adopt such an arrangement of nozzles 54. For example, the nozzle row 55 may be arranged along the short direction (Y direction) of the paint head 53. Also, the nozzle row 55 may be a single nozzle row 55 without being divided into the first nozzle row 55A and the second nozzle row 55B in the short direction (Y direction; main scanning direction) of the paint head 53, or it may be divided into three or more nozzle rows.

[0026] The paint head 53 described above has a flow channel for dispensing paint (not shown) inside. The paint head 53 also has a nozzle pressurizing chamber (not shown) inside, and a piezoelectric substrate 62 (see Figure 2) is placed on one of the walls of the nozzle pressurizing chamber to change the volume of the chamber and discharge paint from the nozzle 54. Therefore, by applying a voltage to the piezoelectric substrate 62 from the outside, the piezoelectric substrate 62 expands and contracts, changing the volume of the nozzle pressurizing chamber and enabling paint to be discharged from the nozzle 54.

[0027] Note that the painting head 53 is not limited to the configuration shown in Figure 3. For example, as shown in Figure 4, a nozzle row 55 may be formed by arranging multiple nozzles 54 along the shorter side (width direction; Y direction) of the painting head 53. Also, when painting a vehicle using a painting head 53 as shown in Figure 4, painting may be performed with the longitudinal direction of the painting head 53 slightly inclined with respect to the main scanning direction of the painting head 53.

[0028] For example, in the configuration of the paint head 53 shown in Figure 3, if the nozzle row 55 is inclined at an angle α with respect to the main scanning direction, then the longitudinal direction of the paint head 53 should be inclined at an angle α with respect to the main scanning direction of the paint head 53. When inclined in this way, painting equivalent to that of the paint head 53 shown in Figure 3 can be achieved simply by adjusting the timing of paint discharge from each nozzle 54.

[0029] (1-6. Controllative Configuration of Painting System 1) Next, the control configuration for controlling the operation of the painting system 1 will be described. The control configuration described below corresponds to the control unit. As shown in Figure 2, the painting robot 10 includes a robot arm control unit 70, a paint supply control unit 80, a head control unit 90, a main control unit 100, a scanner control unit 110, a position sensor 120, a tilt sensor 130, and a 3D scanner 140. The painting robot 10 is connected to the image processing device 200 to constitute the painting system 1. However, the painting robot 10 may also be equipped with the functions of the image processing device 200.

[0030] The robot arm control unit 70, paint supply control unit 80, head control unit 90, main control unit 100, scanner control unit 110, and the image processing unit 210 (described later) are composed of a CPU (Central Processing Unit), memory such as a memory module (ROM (Read Only Memory), RAM (Random Access Memory), non-volatile memory, etc.), and other elements. The image processing unit 210 may use a GPU (Graphics Processing Unit) in conjunction with a CPU that has excellent image processing performance, or in place of the CPU. The memory includes memory 71 in the robot arm control unit 70 and memory 101 in the main control unit 100, but the robot arm control unit 70 and main control unit 100 may also be equipped with other types of memory.

[0031] The painting robot 10 is also equipped with various sensors (not shown in the illustration), and the output from each of these sensors is input to either the robot arm control unit 70, the paint supply control unit 80, the head control unit 90, or the main control unit 100. The various sensors include the position sensor 120, tilt sensor 130, and 3D scanner 140 mentioned above, as well as acceleration sensors, angular velocity sensors, image sensors, etc., but other sensors may also be used.

[0032] Of these components, the robot arm control unit 70 is the part that controls the driving of the motors M1 to M6 mentioned above. This robot arm control unit 70 is equipped with a memory 71, which stores the program and data created by robot teaching.

[0033] The robot arm control unit 70 controls the driving of motors M1 to M6 based on the program and data stored in the memory 71 and the image processing performed by the image processing unit 210 of the image processing device 200. This control allows the painting head unit 50 to pass through the desired position for painting at the desired speed or to stop at a predetermined position.

[0034] Memory 71 stores data related to the trajectory of the painting head 53 (trajectory data) and attitude data related to the tilt of the painting head 53, which are created by robot teaching that takes into account the paint width that can be painted by the painting head 53. Although the painting robot 10 may have memory 71, the memory 71 may be located outside the painting robot 10, and information may be sent and received to and from that memory 71 via wired or wireless communication means.

[0035] Furthermore, the paint supply control unit 80 controls the supply of paint to the painting head unit 50, and specifically controls the operation of the pumps, valves, etc., provided in the paint supply unit 40. Preferably, the paint supply control unit 80 controls the operation of the pumps and valves so that paint is supplied to the painting head unit 50 at a constant pressure.

[0036] Furthermore, the head control unit 90 controls the operation of the piezoelectric substrate 62 in the painting head unit 50 based on image processing in the image processing unit 210. When the head control unit 90 reaches a predetermined position in the trajectory data by means of detecting the position, such as the position sensor 120 and tilt sensor 130 described later, it controls the discharge of paint based on the position and the segmented painting data corresponding to the painting path. In this case, in order to ensure that the film thickness of the painted area is uniform, the drive frequency of the piezoelectric substrate 62 is controlled to control the number of dots (number of droplets) discharged from the nozzle 54, or the deformation amount of the piezoelectric substrate 62 is controlled based on the drive frequency and / or voltage applied to the piezoelectric substrate 62, thereby controlling the size of the droplets discharged from the nozzle 54.

[0037] Furthermore, when controlling the droplet size by controlling the amount of deformation of the piezoelectric substrate 62 based on the driving frequency applied to the piezoelectric substrate 62, the droplet size is largest when the piezoelectric substrate 62 is driven at a driving frequency that matches the natural frequency of the piezoelectric substrate 62. Therefore, as the applied driving frequency deviates from the natural frequency, the droplet size can be controlled to decrease. Also, when controlling the droplet size by controlling the amount of deformation of the piezoelectric substrate 62 based on the voltage applied to the piezoelectric substrate 62, the droplet size can be controlled to increase as the voltage applied to the piezoelectric substrate 62 increases.

[0038] The main control unit 100 transmits predetermined control signals to the robot arm control unit 70, paint supply control unit 80, and head control unit 90 so that the motors M1 to M6, paint supply unit 40, and piezoelectric substrate 62 work together to perform painting on the object to be painted. The main control unit 100 is equipped with a memory 101, which stores the measurement image data D1 (see Figure 7) acquired by the 3D scanner 140. However, instead of having such a memory 101, the measurement image data D1 acquired by the 3D scanner 140 may be stored in the memory 220 of the image processing device 200.

[0039] The scanner control unit 110 controls the operation of the 3D scanner 140. This scanner control unit 110 may be replaced by, for example, the main control unit 100 within the control unit which is the control component of the painting robot 10.

[0040] Furthermore, the position sensor 120 is a sensor that detects the current position of the painting head 53. Various sensors can be used as the position sensor 120, such as a rotary encoder, resolver, laser sensor, and others. Also, the tilt sensor 130 is a sensor that detects the tilt angle of the painting head 53. Various sensors can be used as the tilt sensor 130, such as a gyro sensor or accelerometer.

[0041] In this embodiment, a vibration sensor 150, different from the position sensor 120 and tilt sensor 130 described above, may also be provided. Preferably, this vibration sensor 150 is attached to any part of the painting head unit 50 so as to detect vibrations in the 3D scanner 140 (painting head 53).

[0042] Furthermore, the painting robot 10 is equipped with a 3D scanner 140. This 3D scanner 140 is a sensor that can acquire height (thickness) data in addition to acquiring planar 2D data. Examples of such 3D scanners 140 include LiDAR scanners, laser scanners, and photogrammetry. The 3D scanner 140 corresponds to an image acquisition means.

[0043] This 3D scanner 140 is attached, for example, to the painting head unit 50. Therefore, when acquiring 3D data of the painting area, as described later, the robot arm R1 is activated. However, the 3D scanner 140 may be provided separately from the painting head unit 50. In such a configuration, for example, the 3D scanner 140 may be attached to a predetermined part of the robot arm R1, separate from the painting head unit 50. Alternatively, a dedicated arm for attaching the 3D scanner 140 may be provided on the painting robot 10, and the 3D scanner 140 may be attached to that arm.

[0044] Furthermore, the painting system 1 is equipped with an image processing device 200. The image processing device 200 comprises an image processing unit 210 and a memory 220.

[0045] The image processing unit 210 is the part that creates image data for each painting path, which is the path through which the painting head 53 performs painting.

[0046] Furthermore, the memory 220 stores the measurement image data D1 transmitted from the main control unit 100, as well as the correction paint data C1 created by the image processing unit 210, and is a part that stores image data and other data.

[0047] The image processing device 200 may be, for example, a computer, but this computer may be a component of the painting robot 10, or it may be provided separately from the painting robot 10. If the image processing device 200 is provided separately from the painting robot 10, data will be transmitted and received between the image processing device 200 and the painting robot 10 by wired communication or wireless communication. Even if the image processing device 200 is provided separately from the painting robot 10, it may be included in the concept of the painting robot 10, or it may not be included in the concept of the painting robot 10.

[0048] (2. Regarding control when creating corrective painting data and executing painting during the painting process) Next, we will describe the control process for creating corrective painting data and executing painting in the painting system 1 and painting robot 10 configured as described above. The corrective painting data is image data for painting that reflects the vibration state of the painting head 53 (vibration amplitude, frequency, wavelength, etc.) in order to suppress the deviation of the droplet landing position due to the vibration of the painting head 53.

[0049] The control process for creating the correction painting data will be explained based on the flowchart in Figure 5. First, the main control unit 100 commands the robot arm control unit 70 to read the measurement image S1 shown in Figure 6 with the 3D scanner 140, and also activates the 3D scanner 140 (step S01). As a result, the robot arm R1 operates, and the 3D scanner 140 attached to the painting head 53 scans the measurement image S1 (step S02).

[0050] Here, an example of a measurement image S1 is shown in Figure 6. Note that the measurement image S1 is the painted area captured during scanning with the 3D scanner 140. In the state shown in Figure 6, the measurement image S1 is a long, narrow rectangle, but its shape can be anything. Furthermore, the measurement image S1 may have irregularities in the thickness direction.

[0051] Based on the measurement image S1 shown in Figure 6, the robot arm control unit 70 operates the robot arm R1 in response to a command from the main control unit 100, and the scanner control unit 110 operates the 3D scanner 140. Then, the measurement image S1 is scanned by the 3D scanner 140 to acquire measurement image data D1 as shown in Figure 7 (step S03).

[0052] The measurement image data D1 reflects the current physical state of the painting head 53 (such as the viscosity of the paint due to temperature and pressure, and the mechanical characteristics of each part of the painting robot 10) as vibrations.

[0053] Incidentally, in the measurement image S1 shown in Figure 6 above, the edge S1a is straight. Therefore, if there is no vibration in the painting head 53, when the measurement image S1 is scanned with the 3D scanner 140 attached to the painting head 53, the edge D1a in the measurement image data D1 (see Figure 7) obtained by the scan should be straight.

[0054] However, vibrations often occur in the painting head 53 due to the influence of vibrations from the robot arm R1 and other components. Therefore, the vibrations of the painting head 53 are reflected in the measurement image data D1 obtained by scanning with the 3D scanner 140, for example, as shown in Figure 7. At this time, when moving along the edge D1a of the measurement image data D1, for example in the direction corresponding to the scanning direction of the painting head 53 (main scanning direction) (vertical direction in Figure 7), a wave shape vibrating with a predetermined period is formed.

[0055] In the measurement image data D1 shown in Figure 7, the direction corresponding to the scanning direction of the coating head 53 (main scanning direction) (vertical direction in Figure 7) is defined as the y-direction, and the direction corresponding to the sub-scanning direction perpendicular to the main scanning direction (horizontal direction in Figure 7) is defined as the x-direction. In this case, the effect of vibration of the coating head 53 is mainly reflected in the x-direction in the measurement image data D1. However, in the measurement image data D1, the effect of vibration may also be reflected in the y-direction (vertical direction in Figure 7), which is the main scanning direction, and in the z-direction, which is the thickness direction (this point will be discussed later).

[0056] As described above, when the measurement image data D1 reflects the effects of vibration, if paint droplets are ejected from the nozzle 54 of the painting head 53 based on the image data for painting, the point of impact will be shifted by the amount of the vibration effect.

[0057] Therefore, in order to eliminate this discrepancy, the main control unit 100 transmits the acquired measurement image data D1 to the image processing device 200, as shown in Figure 7 (step S04). The image processing unit 210 of the image processing device 200 then performs image processing (correction) on the image data for painting to eliminate the discrepancy in the paint's impact position, and as a result, creates corrected painting data C1, as shown in Figure 8 (step S05). In the corrected painting data C1 shown in Figure 8, correction (image processing) is performed on the image data for painting so that vibrations are applied that are in the opposite phase to the vibrations that are affecting the measurement image data D1.

[0058] Here, we consider a case where measurement image data D1 is acquired by scanning the measurement image S1, and a positional shift of +x1 occurs at a predetermined position P1 in the measurement image S1 due to the effect of vibration (see Figure 7). At this time, we consider forming a painted area with the same shape as the measurement image S1. In this case, the correction painting data C1 is processed to shift the position by -x1 in order to eliminate the +x1 positional shift at the predetermined position P1. In other words, the correction painting data C1 for painting is created by applying vibrations that are in the opposite phase to the vibrations occurring in the measurement image data D1.

[0059] The correction painting data C1 created as described above is transmitted from the image processing device 200 to the main control unit 100, and the correction painting data C1 is stored in the memory 101 (step S06). Then, in the painting robot 10, the robot arm control unit 70 controls the operation of the robot arm R1 so that the painting head 53 moves to a predetermined position to be painted, according to a command from the main control unit 100. Also, according to a command from the main control unit 100, the paint supply control unit 80 discharges droplets from the nozzle 54 based on the correction painting data C1. That is, painting is performed on the painting area (step S10).

[0060] Furthermore, even when corrective coating data C1 is created as described above, positional errors may still occur. In other words, for normal coating that does not take vibration into consideration, the accuracy of the droplet's landing position can be improved by measuring with a position sensor 120, etc. However, when vibration occurs, even if one tries to land the droplet in the same position, a positional error of +x1 will occur at time t1 when the vibration amplitude is +x1, and a positional error of -x2 will occur at another time t2 when the vibration amplitude is -x2, etc., and the position cannot be determined solely by measuring the position with a position sensor 120, etc.

[0061] Furthermore, when vibration occurs in the painting head 53, it is usually unclear at what point in the vibration state the painting head 53 began to move.

[0062] Therefore, when actually performing painting, the following procedure may be followed. That is, when starting painting, the painting head 53 is placed in a predetermined standby position (step S07). While the painting head 53 is in this standby position, sensors such as the tilt sensor 130 (or the vibration sensor 150 if one is present) measure the vibration state of the painting head 53 (step S08).

[0063] In measuring such vibrations, when the vibration of the painting head 53 reaches a predetermined phase, the robot arm control unit 70 activates the robot arm R1 to move the painting head 53 to the painting area (step S09). In this way, it is possible to suppress the amplification of vibration effects, which would otherwise occur during painting by the painting head 53, instead of eliminating them.

[0064] Furthermore, in the vibration measurement in step S08, it is preferable to adjust the movement speed of the painting head 53 based on the frequency measured in the vibration state measurement in step S08. When adjusting the movement speed of the painting head 53 in this way, it is possible to suppress the phase shift of the correction painting data C1, which is created to be in the opposite phase to the vibration state of the painting head 53.

[0065] Furthermore, the vibration of the painting head 53 rarely occurs only along the x-direction, which is the sub-scanning direction. Its vibration equation typically has x-components, y-components, and z-components in the three-dimensional space of x, y, and z, respectively.

[0066] Therefore, when creating corrective coating data C1 to apply vibrations that are out of phase with the vibrations occurring in the measured image data D1, it is preferable to correct (process) the measured image data D1 so that not only the x-direction component, but also the y-direction and z-direction components are given vibrations that are out of phase with the vibrations in each respective direction, and then create the corrective coating data C1. In this way, by creating corrective coating data C1 to apply vibrations that are out of phase with the vibrations occurring in the x, y, and z directions in the measured image data D1, the influence of vibrations during coating can be reduced in the y-direction, which is the main scanning direction, and the z-direction, which is the thickness direction.

[0067] Furthermore, if the vibration of the paint head 53 extends to the edges of the area to be painted, if painting data that causes droplets to be ejected from all nozzles 54 is created in a normal painting process without vibration, it may become impossible to eliminate the vibration of the paint head 53. This is because the vibration of the paint head 53 could result in a situation where the nozzles 54 are not present (not positioned) in the area that should be painted.

[0068] Therefore, when the image processing device 200 (image processing unit 210) creates the corrective painting data C1 for painting, as shown in Figure 9, the nozzles 54 within a predetermined range from the end in the sub-scanning direction are designated as the corrective nozzles 54C. On the other hand, the nozzles 54 located closer to the center of the painting head 53 than the predetermined range from the end in the sub-scanning direction are designated as the normal painting nozzles 54N.

[0069] Furthermore, in the image processing of the image processing device 200 (image processing unit 210), assuming that the painting head 53 is not vibrating, the edge E1a of the painting data E1, which is the data for painting the painting area, is set so that it does not come into contact with the correction nozzle 54C. In addition, correction painting data C1 for painting is created so that the vibration at the edge E1a of the painting data E1 is absorbed by the correction nozzle 54C. In this way, when the painting head 53 vibrates, the amplitude of that vibration can be absorbed by the correction nozzle 54C.

[0070] (3. Variant) Although one embodiment of the present invention has been described above, the present invention can be modified in various ways other than the above embodiment. Modifications are described below.

[0071] The above-described embodiment explains the case in which a 3D scanner 140 is used as the image acquisition means. However, the image acquisition means is not limited to a 3D scanner 140. For example, a 2D camera using a CCD (Charge-Coupled Device) sensor or a CMOS (Complementary Metal Oxide Semiconductor) sensor, or a line sensor capable of scanning in a predetermined direction may be used.

[0072] Furthermore, as a 3D scanner 140, for example, if a configuration is made that can acquire 3D data by combining multiple ordinary cameras capable of acquiring 2D data, then this combination of multiple cameras corresponds to the 3D scanner 140 as defined in the present invention.

[0073] Furthermore, in the above-described embodiment, it may be estimated that the vibration state of the painting head 53 has changed due to some abnormal factor, such as the occurrence of abnormal motor vibration. In such cases, when new measurement image data D1 as shown in Figure 7 is acquired, it is also possible to use this new measurement image data D1 for anomaly detection by comparing it with previously acquired measurement image data D1.

[0074] Furthermore, in the above-described embodiment, when analyzing newly acquired measurement image data D1, it is conceivable to detect abnormal values ​​such as significantly larger amplitudes by comparing them with previously acquired measurement image data D1. The detection of such abnormal values ​​may be used for anomaly detection, for example, by having the painting robot 10 issue an alert, or the painting may be stopped based on the detection of such anomalies. This may help to avoid painting under abnormal conditions and increase the success rate of painting using the correction painting data C1.

[0075] (4. Note) The contents described in the above-mentioned embodiment can be understood, for example, as follows: [1] That is, A painting system 1 for painting a predetermined part of a vehicle, A painting head unit 50 is provided with a painting head 53 having multiple nozzles 54 for dispensing paint droplets, A robotic arm R1 is equipped with a painting head unit 50 at its tip and moves the painting head unit 50 to a desired position. A 3D scanner 140 (image acquisition means) acquires painting data of the painted area painted by the painting head 53, The system includes a control unit (main control unit 100, robot arm control unit 70, head control unit 90, scanner control unit 110) that controls the operation of the 3D scanner 140 (image acquisition means) and the operation of the painting head 53 and robot arm R1, The control unit (main control unit 100, robot arm control unit 70, head control unit 90, main control unit 100) is, The 3D scanner 140 (image acquisition means) is activated, and before painting is performed, the measurement image S1 is scanned with the 3D scanner 140 (image acquisition means) to acquire measurement image data D1 that reflects the vibration state of the 3D scanner 140 (image acquisition means). Based on the measurement image data D1 acquired by the 3D scanner 140 (image acquisition means), correction painting data C1 is created to eliminate the misalignment of the landing position of the droplets ejected from the painting head 53. Based on the correction painting data C1, the robot arm R1 and painting head 53 are driven and controlled.

[0076] In this way, by measuring the vibration state (fluctuations) of the 3D scanner 140 (image acquisition means) and creating corrective painting data C1 that eliminates the deviation in the impact position based on that vibration state (fluctuation), it becomes possible to eliminate the deviation in the impact position of the droplets ejected from the painting head 53. As a result, high-definition painting becomes possible, with the effects of the vibration state (fluctuations) eliminated.

[0077] [2] In addition, in the above embodiment, in addition to the contents described in [1] above, The image acquisition means is a 3D scanner 140 that acquires 3D painting data of the painted area. The control unit (main control unit 100, robot arm control unit 70, head control unit 90, scanner control unit 110) may create corrective painting data C1 to eliminate the displacement of the impact position in the thickness direction of the painted area, as well as the displacement of the impact position in the thickness direction of the painted area, based on the measurement of the measurement image S1 before painting is performed.

[0078] In this way, by using a 3D scanner 140 as an image acquisition method and creating corrective painting data C1 based on the measurement of the measurement image S1 by the 3D scanner 140, it becomes possible to eliminate not only the displacement of the droplet landing position in the planar direction of the painted area, but also the displacement of the droplet landing position in the thickness direction of the painted area. As a result, high-definition painting becomes possible, in which the effects of vibration (fluctuations) are eliminated in three dimensions.

[0079] [3] In addition, in the above embodiment, in addition to the contents described in [1] and [2] above, or a combination thereof, The 3D scanner 140 (image acquisition means) may be fixed to the painting head 53.

[0080] In this way, by fixing the 3D scanner 140 to the painting head 53, it becomes possible to measure the vibration state of the painting head 53 with high precision. As a result, it becomes possible to predict the deviation of the impact position based on the vibration state (fluctuation) with high precision, and high-definition painting becomes possible, eliminating the effects of fluctuation.

[0081] [4] In addition, in the above embodiment, in addition to the contents described in any of [1] to [3] above or a combination thereof, The control units (main control unit 100, robot arm control unit 70, head control unit 90, scanner control unit 110) may create the correction painting data in the opposite phase to the vibration state.

[0082] In this way, by creating corrective painting data C1 in the opposite phase to the vibration state, it becomes possible to achieve high-definition painting with the effects of the vibration state (fluctuations) eliminated.

[0083] [5] In addition, in the above embodiment, in addition to the contents described in any of [1] to [4] above or a combination thereof, When the vibration state affects the edges of the painted area, among the range of nozzles 54 on the nozzle forming surface 52 of the painting head 53, nozzles 54 within a predetermined range from the end in the sub-scanning direction of the painting head 53 are designated as correction nozzles 54C, and nozzles 54 located closer to the center of the painting head 53 than that predetermined range are designated as normal painting nozzles 54N. The control units (main control unit 100, robot arm control unit 70, head control unit 90, scanner control unit 110) are: Assuming the painting head 53 is not vibrating, the edges of the painting data, which are the data for painting the area to be painted, do not come into contact with the correction nozzle 54C. Alternatively, correction paint data C1 may be created so that vibrations at the edges of the paint data are absorbed by the correction nozzle 54C.

[0084] By painting in this manner, while the painting of the area to be painted is performed by the discharge of liquid droplets from the normal painting nozzle 54N, the outer nozzle 54 is used as a correction nozzle 54C for painting. This allows the amplitude of vibrations in the painting head 53 to be absorbed by the correction nozzle 54C. Therefore, the effects of deviations in the landing position of the liquid droplets can be effectively eliminated. [Explanation of Symbols]

[0085] 1…Painting system, 10…Painting robot, 20…Robot body, 21…Base, 22a…First rotation axis, 22b…Second rotation axis, 22c…Third rotation axis, 22d…Fourth rotation axis, 22e…Fifth rotation axis, 22f…Sixth rotation axis, 23…Legs, 24…First rotating arm, 25…Second rotating arm, 26…Rotating arm, 27…Wrist section, 40…Paint supply section, 41…Supply path, 42…Return path, 50…Painting head unit, 52…Nozzle forming surface, 53…Painting head, 54…Nozzle, 54C…Correction nozzle, 54N…Normal painting nozzle, 55…Nozzle row, 55A…First nozzle row, 55B…Second nozzle row, 62…Piezoelectric substrate, 70… Robot arm control unit (corresponding to part of the control unit), 71...Memory, 80...Paint supply control unit, 90...Head control unit (corresponding to part of the control unit), 100...Main control unit (corresponding to part of the control unit), 101...Memory, 110...Scanner control unit (corresponding to part of the control unit), 120...Position sensor, 130...Tilt sensor, 140...3D scanner, 150...Vibration sensor, 200...Image processing unit, 210...Image processing unit, 220...Memory, C1...Correction painting data, D1...Measurement image data, D1a...Edge, E1...Painting data, E1a...Edge, M1~M6...Motor, R1...Robot arm, S1...Measurement image, S1a...Edge

Claims

1. A painting system comprising a painting robot that paints the painted parts of a vehicle, A painting head unit comprising a painting head having multiple nozzles for dispensing paint droplets, A robotic arm, to which the aforementioned painting head unit is attached, and which moves the painting head unit to a desired position, An image acquisition means for acquiring painting data of the painted area painted by the aforementioned painting head, The system includes a control unit that controls the operation of the image acquisition means and the operation of the painting head and the robot arm, The control unit, The image acquisition means is activated, and before painting is performed, the measurement image is scanned with the image acquisition means to obtain measurement image data that reflects the vibration state of the image acquisition means. Based on the measurement image data acquired by the image acquisition means, correction painting data is created to eliminate the misalignment of the landing position of the droplets ejected from the painting head. Based on the corrective painting data, the robot arm and the painting head are driven and controlled. A painting system characterized by the following features.

2. A coating system according to claim 1, The image acquisition means is a three-dimensional scanner that acquires three-dimensional painting data of the painted area. The control unit, based on the measurement of the measurement image before the painting is performed, creates correction painting data to correct the deviation of the impact position in the thickness direction of the painted area, along with the deviation of the impact position in the thickness direction of the painted area. A painting system characterized by the following features.

3. A coating system according to claim 1, The image acquisition means is fixed to the painting head. A painting system characterized by the following features.

4. A coating system according to claim 1, The control unit creates the correction painting data in the opposite phase to the vibration state. A painting system characterized by the following features.

5. A coating system according to claim 1, When the vibration state affects the edges of the painted area, the nozzles within a predetermined range from the end in the sub-scanning direction of the painting head are designated as correction nozzles, and the nozzles located closer to the center of the painting head than that predetermined range are designated as normal painting nozzles. The control unit, Assuming the painting head is not in the vibrating state, the edges of the painting data, which are the data for painting the painting area, do not come into contact with the correction nozzle, The correction painting data is created so that vibrations at the edges of the painting data are absorbed by the correction nozzle. A painting system characterized by the following features.

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