Painting System

Abstract

To provide a coating system capable of improving coating quality even when fluctuations such as vibrations occur in an image acquisition means. [Solution] The painting system 1 comprises a painting head unit 50 with a painting head 53, a robot arm R1 that moves the painting head unit 50 to a desired position, an image acquisition means that acquires painting data for the area to be painted, 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 and acquire measurement image data that reflects the vibration state of the image acquisition means, creates corrective painting data based on the measurement image data acquired by the image acquisition means to eliminate deviations in the landing positions of droplets, and performs drive control of the robot arm and painting head based on the corrective painting data.

Description

[Technical field]

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

[0002] Robot painting using robots has become mainstream in painting lines for vehicles such as automobiles. As an example of a configuration related to this robot painting, for example, Patent Document 1 discloses the following configuration. In the painting robot disclosed in Patent Document 1, a technique is disclosed in which nozzle discharge defects are judged based on a test pattern having multiple check lines. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2023-009853 A Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, the configuration disclosed in Patent Document 1 discloses that 3D image data is generated from imaging data obtained from multiple imaging units, but does not disclose how to resolve discharge defects caused by fluctuations such as vibrations of the 3D scanner. If droplets are discharged from the coating head without knowing that there are fluctuations, there is a risk that the droplets will land at a position different from the intended landing position.

[0005] The present invention has been made in light of the above circumstances, and has an object to provide a painting system that is capable of improving painting quality even if fluctuations such as vibrations occur in the image acquisition means. [Means for solving the problem]

[0006] In order to solve the above problems, according to a first aspect of the present invention, there is provided a painting system including a painting robot that paints a painting area of ​​a vehicle, the painting system including: a paint head unit including a paint head having a plurality of nozzles that eject paint droplets; a robot arm to which the paint head unit is attached and which moves the paint head unit to a desired position; an image acquisition means that acquires painting data of the painting area painted by the paint head; and a control unit that controls the operation of the image acquisition means and controls the operation of the paint 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 and acquire measurement image data that reflects the vibration state of the image acquisition means, creates correction painting data based on the measurement image data acquired by the image acquisition means to eliminate deviations in the landing positions of the droplets ejected from the paint head, and performs drive control of the robot arm and the paint head based on the correction painting data. Effect of the Invention

[0007] According to the present invention, it is possible to provide a coating system capable of improving coating quality even if fluctuations such as vibrations occur in the image acquisition means. [Brief description of the drawings]

[0008] [Figure 1] 1 is a schematic diagram showing an overall configuration of a painting robot according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a diagram showing a schematic configuration of a painting system including the painting robot shown in FIG. [Diagram 3] 2 is a diagram showing a front view of a nozzle forming surface for ejecting paint in a paint head unit included in the paint robot shown in FIG. 1. FIG. [Figure 4] 4 is a plan view showing the configuration of a nozzle forming surface of a paint head unit different from the paint head unit shown in FIG. 3. [Diagram 5]4 is a diagram showing a flow of control when corrective painting data is created and painting is performed in the painting robot shown in FIG. 1. [Figure 6] 2 is a diagram showing an example of a measurement image scanned by a three-dimensional scanner provided in the painting robot shown in FIG. 1. [Figure 7] 2 is a diagram showing measurement image data obtained by scanning with a three-dimensional scanner provided in the painting robot shown in FIG. 1. [Figure 8] FIG. 8 is a diagram showing corrective coating data created based on the measured image data shown in FIG. 7. [Figure 9] 2 is a diagram showing a normal painting nozzle and a correction nozzle in a painting head provided in the painting robot shown in FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0010] (1. Overview of Paint Robot 10) The painting robot 10 of this embodiment "paints" 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 factory, and aims to form a paint film on the surface of the object to be painted to protect the surface and provide a beautiful appearance. Therefore, it is necessary to paint vehicles that move along the painting line at predetermined intervals within a certain time with the desired painting quality.

[0011] Furthermore, the painting robot 10 of this embodiment is capable of forming not only the above-mentioned coating film but also 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, and may be any parts other than automobiles (for example, exterior parts of airplanes and trains) that require painting.

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

[0013] (1-2. About Paint Robot 10) As shown in Fig. 1, the painting robot 10 mainly comprises a robot body 20 and a painting head unit 50. The painting robot 10 shown in Fig. 1 is, as an example, a six-axis vertical articulated robot, but the painting robot 10 may be any type of robot, such as a vertical articulated type other than six axes, a horizontal articulated type, or an Cartesian robot.

[0014] (1-3. Regarding the robot body 20) 1, the robot body 20 mainly comprises a base 21, first to sixth rotating shafts 22a to 22f, legs 23, a first rotating arm 24, a second rotating arm 25, a rotating arm 26, a wrist 27, and motors M1 to M6 for driving these. Note that the portion from the legs 23 to the wrist 27 corresponds to the robot arm R1, but other portions such as the base 21 may also correspond to the robot arm R1.

[0015] Of these, the base 21 is a part that is installed on an installation site such as a floor surface, but the base 21 may be movable relative to the installation site. The legs 23 are parts that stand upward from the base 21, and are provided rotatable relative to the base 21 via a first rotating shaft 22a by driving a motor M1 (see FIG. 2). The legs 23 may be configured not to rotate relative to the base 21.

[0016] A first rotating arm 24 is provided on the upper end of leg 23 so as to be rotatable about second rotating shaft 22b by driving of motor M2. Furthermore, a second rotating arm 25 is provided on the tip side of first rotating arm 24 so as to be rotatable about third rotating shaft 22c by driving of motor M3.

[0017] A rotating arm 26 is provided at the tip of the second rotating arm 25 so as to be rotatable around the central axis of the second rotating arm 25. The rotating arm 26 is rotatable around a fourth rotating shaft 22d by the drive of the motor M4. A wrist section 27 is provided at the tip of the rotating arm 26. The wrist section 27 is capable of rotating around a plurality of shafts, for example, two, in different directions, by the drive of the motors M5 and M6. In FIG. 1, the rotating shafts capable of the rotating motion are the fifth rotating shaft 22e and the sixth rotating shaft 22f, respectively. This makes it possible to control the orientation of the painting head unit 50 with high precision. The number of shafts may be any number greater than or equal to two.

[0018] Further, a painting head unit 50 is attached to the wrist portion 27, but this painting head unit 50 may be provided so as to be detachable from the wrist portion 27.

[0019] (1-4. Regarding the paint supply unit 40) 2, the painting system 1 and the painting robot 10 are provided with a paint supply unit 40. The paint supply unit 40 is a part for supplying paint to the painting head unit 50. For this reason, the paint supply unit 40 is provided with a supply path 41 for supplying paint from a paint storage unit (not shown), a pump (not shown), a valve (not shown), and a return flow path 42 for recovering paint that has not been discharged.

[0020] In addition, when a configuration is adopted in which paint is supplied from outside the painting robot 10, the painting robot 10 does not need to have a section for storing paint, and may have a section for storing paint outside the painting robot 10.

[0021] (1-5. About the painting head unit 50) Next, the painting head unit 50 will be described. Fig. 3 is a diagram showing a front view of the nozzle forming surface 52 from which paint is ejected of the painting head unit 50. As shown in Fig. 3, the painting head unit 50 is provided with a head cover (not shown), and various components including a painting head 53 are built into the head cover. The painting head 53 is provided with a large number of nozzles 54 for ejecting paint.

[0022] 3, the openings of a plurality of nozzles 54 are exposed on the paint ejecting surface (nozzle forming surface 52) of the paint head 53. In the following description, the openings of the nozzles 54 will also be referred to as nozzles 54.

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

[0024] When discharging paint, the drive timing of each nozzle 54 is controlled so that droplets discharged from nozzles 54 in the second nozzle row 55B land between droplets discharged from adjacent nozzles 54 in the first nozzle row 55A, thereby improving the dot density during coating.

[0025] 3, the arrangement of the nozzles 54 in the first nozzle row 55A and the arrangement of the nozzles 54 in the second nozzle row 55B are inclined with respect to the short side direction (Y direction; main scanning direction) of the paint head 53. However, such an arrangement of the nozzles 54 does not have to be adopted. For example, the nozzle row 55 may be arranged along the short side direction (Y direction) of the paint head 53. Furthermore, the nozzle row 55 may not be divided into the first nozzle row 55A and the second nozzle row 55B in the short side direction (Y direction; main scanning direction) of the paint head 53, but may be one nozzle row 55, or may be divided into three or more nozzle rows.

[0026] A flow path for flowing paint (not shown) is provided inside the paint head 53. A nozzle pressurizing chamber (not shown) is also provided inside the paint head 53, and a piezoelectric substrate 62 (see FIG. 2) is disposed on one of the walls of the nozzle pressurizing chamber for changing the volume of the nozzle pressurizing chamber to eject 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, making it possible to eject paint from the nozzle 54.

[0027] The paint head 53 is not limited to the configuration shown in Fig. 3. For example, as shown in Fig. 4, a plurality of nozzles 54 may be arranged along the short side direction (width direction; Y direction) of the paint head 53 to form a nozzle row 55. When painting a vehicle using the paint head 53 as shown in Fig. 4, painting may be performed with the longitudinal direction of the paint head 53 slightly inclined with respect to the main scanning direction of the paint head 53.

[0028] For example, in the configuration of the paint head 53 shown in Fig. 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 can be inclined at the angle α with respect to the main scanning direction of the paint head 53. When inclined in this manner, painting equivalent to that of the paint head 53 shown in Fig. 3 can be achieved simply by adjusting the timing of paint ejection from each nozzle 54.

[0029] (1-6. Control configuration of painting system 1) Next, a 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 Fig. 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, an inclination sensor 130, and a three-dimensional scanner 140. The painting robot 10 is connected to an image processing device 200 to configure the painting system 1. However, the painting robot 10 may also include the functions of the image processing device 200.

[0030] The robot arm control unit 70, the paint supply control unit 80, the head control unit 90, the main control unit 100, the scanner control unit 110, and the image processing unit 210 described below are composed of a CPU (Central Processing Unit), memories such as storage units (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) together with a CPU with excellent image processing performance, or instead of a CPU. The memories include the memory 71 in the robot arm control unit 70 and the memory 101 in the main control unit 100, but the robot arm control unit 70 and the main control unit 100 may be equipped with other memories.

[0031] The painting robot 10 is also equipped with various sensors (not shown), and outputs from each of these sensors are input to 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 above-mentioned position sensor 120, tilt sensor 130, and 3D scanner 140, and further include an acceleration sensor, an angular velocity sensor, an image sensor, etc., but sensors other than these may also be used.

[0032] Among these, the robot arm control unit 70 is a part that controls the driving of the above-mentioned motors M1 to M6. The robot arm control unit 70 includes a memory 71, and the memory 71 stores programs and data created by robot teaching.

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

[0034] The memory 71 stores data on the trajectory of the paint head 53 (trajectory data) and posture data on the posture, such as the tilt, of the paint head 53, which are created by robot teaching taking into account the painting width that the paint head 53 can paint. Note that the memory 71 may be provided in the paint robot 10, but it may also be possible for the memory 71 to exist outside the paint robot 10 and for information to be sent and received to the memory 71 via wired or wireless communication means.

[0035] The paint supply control unit 80 is a part that controls the supply of paint to the paint head unit 50, and specifically controls the operation of pumps, valves, and the like provided in the paint supply unit 40. Note that it is preferable that the paint supply control unit 80 controls the operation of the pumps and valves so that paint is supplied at a constant pressure to the paint head unit 50 to which paint is supplied.

[0036] The head control unit 90 is a part that controls the operation of the piezoelectric substrate 62 in the paint head unit 50 based on the image processing in the image processing unit 210. When the head control unit 90 reaches a predetermined position in the trajectory data by a means for detecting the position, such as a position sensor 120 and an inclination sensor 130, which will be described later, the head control unit 90 controls the discharge of paint based on the divided paint data corresponding to the position and the paint pass. In this case, the drive frequency of the piezoelectric substrate 62 is controlled to control the number of dots (the number of droplets) discharged from the nozzle 54, and 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, so that the film thickness of the painted area is uniform.

[0037] When controlling the droplet size by controlling the deformation amount of the piezoelectric substrate 62 based on the drive frequency applied to the piezoelectric substrate 62, the droplet size becomes largest when the piezoelectric substrate 62 is driven at a drive frequency that matches the natural frequency of the piezoelectric substrate 62. Therefore, the droplet size can be controlled to become smaller as the applied drive frequency deviates from the natural frequency. When controlling the droplet size by controlling the deformation amount of the piezoelectric substrate 62 based on the voltage applied to the piezoelectric substrate 62, the droplet size can be controlled to become larger as the voltage applied to the piezoelectric substrate 62 becomes higher.

[0038] The main control unit 100 is a part that transmits predetermined control signals to the above-mentioned robot arm control unit 70, paint supply control unit 80, and head control unit 90 so that the above-mentioned motors M1 to M6, paint supply unit 40, and piezoelectric substrate 62 work together to paint the object to be painted. The main control unit 100 includes a memory 101, which stores measured image data D1 (see FIG. 7) acquired by the three-dimensional scanner 140. However, without including such a memory 101, the measured image data D1 acquired by the three-dimensional scanner 140 may be stored in a memory 220 of the image processing device 200.

[0039] The scanner control unit 110 controls the operation of the three-dimensional scanner 140. The scanner control unit 110 may be substituted by, for example, the main control unit 100 within the control unit that is a control configuration of the painting robot 10.

[0040] Moreover, the position sensor 120 is a sensor that detects the current position of the paint head 53. Various sensors such as a rotary encoder, a resolver, a laser sensor, etc. can be used as the position sensor 120. Moreover, the tilt sensor 130 is a sensor that detects the tilt angle of the paint head 53. Various sensors such as a gyro sensor, an acceleration sensor, etc. can be used as the tilt sensor 130.

[0041] In this embodiment, a vibration sensor 150 may be provided in addition to the position sensor 120 and the tilt sensor 130. This vibration sensor 150 is preferably attached to any location of the paint head unit 50 so as to detect vibrations in the 3D scanner 140 (paint head 53).

[0042] The painting robot 10 is also equipped with a three-dimensional scanner 140. The three-dimensional scanner 140 is a sensor that can acquire height (thickness) data in addition to acquiring planar two-dimensional data. Examples of such a three-dimensional scanner 140 include a LiDAR scanner, a laser scanner, and photogrammetry. The three-dimensional scanner 140 corresponds to an image acquisition means.

[0043] The three-dimensional scanner 140 is attached to, for example, the paint head unit 50. Therefore, when acquiring three-dimensional data of a painted part, which will be described later, the robot arm R1 is operated. However, the three-dimensional scanner 140 may be provided separately from the paint head unit 50. In such a configuration, for example, the three-dimensional scanner 140 may be provided at a predetermined position of the robot arm R1 separate from the paint head unit 50. Also, a configuration may be adopted in which a dedicated arm for attaching the three-dimensional scanner 140 to the paint robot 10 is provided, and the three-dimensional scanner 140 is attached to the arm.

[0044] The painting system 1 is also provided with an image processing device 200. The image processing device 200 includes an image processing unit 210 and a memory 220.

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

[0046] The memory 220 is a part that stores image data and other data, such as storing the measured image data D1 transmitted from the main control unit 100 and storing the corrective painting data C1 created by the image processing unit 210.

[0047] The image processing device 200 corresponds to, for example, a computer, but the computer may be a part of the painting robot 10 or may be provided separately from the painting robot 10. When the image processing device 200 is provided separately from the painting robot 10, data is 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 may not be included in the concept of the painting robot 10.

[0048] (2. Regarding control when creating corrective painting data and executing painting) Next, a description will be given of the control when creating corrective painting data and performing 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 (amplitude, frequency, wavelength, etc. of vibration) so as to suppress deviation of the landing position of droplets due to vibration of the painting head 53.

[0049] The control for creating such corrective painting data will be described with reference to the flowchart in Fig. 5. First, the main control unit 100 issues a command to the robot arm control unit 70 to read a measurement image S1 as shown in Fig. 6 with the 3D scanner 140, and operates the 3D scanner 140 (step S01). This causes the robot arm R1 to operate, and the 3D scanner 140 attached to the painting head 53 scans the measurement image S1 (step S02).

[0050] An example of the measurement image S1 is shown in Fig. 6. The measurement image S1 is a painted portion that is imaged during scanning by the three-dimensional scanner 140. The measurement image S1 has a long and narrow rectangular shape in the state shown in Fig. 6, but the shape may be any shape. The measurement image S1 may also have irregularities in the thickness direction.

[0051] In response to a command from the main control unit 100 for the measurement image S1 shown in Fig. 6, the robot arm control unit 70 operates the robot arm R1 and the scanner control unit 110 operates the three-dimensional scanner 140. Then, the measurement image S1 is scanned by the three-dimensional scanner 140 to obtain measurement image data D1 as shown in Fig. 7 (step S03).

[0052] The measured 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) in the form of vibrations.

[0053] Incidentally, the edge S1a is linear in the measurement image S1 shown in Fig. 6. Therefore, when the measurement image S1 is scanned by the 3D scanner 140 attached to the paint head 53 in the absence of vibration in the paint head 53, the edge D1a should be linear in the measurement image data D1 (see Fig. 7) obtained by the scan.

[0054] However, vibrations of the robot arm R1 and other components often occur in the paint head 53. For this reason, the vibrations of the paint head 53 are reflected in the measured image data D1 obtained by scanning with the 3D scanner 140, as shown in Fig. 7 for example. At this time, when the paint head 53 moves in a direction (vertical direction in Fig. 7) corresponding to the scanning direction (main scanning direction) along the edge D1a of the measured image data D1, a wave shape that vibrates at a predetermined period is formed.

[0055] In the measured image data D1 shown in Fig. 7, the direction (vertical direction in Fig. 7) corresponding to the direction in which the paint head 53 scans (main scanning direction) is defined as the y direction, and the direction (horizontal direction in Fig. 7) corresponding to the sub-scanning direction perpendicular to the main scanning direction is defined as the x direction. In this case, the measured image data D1 mainly reflects the influence of vibration of the paint head 53 in the x direction. However, in the measured image data D1, the influence of vibration may also be reflected in the y direction (vertical direction in Fig. 7), which is the main scanning direction, or in the z direction, which is the thickness direction (this point will be described later).

[0056] As described above, when the effects of vibration are reflected in the measured image data D1, when paint droplets are ejected from the nozzle 54 of the painting head 53 based on the image data for painting, the landing position will be shifted by an amount equal to the effects of the vibration.

[0057] In order to eliminate such deviations, the main control unit 100 transmits the acquired measured image data D1 as shown in Fig. 7 to the image processing device 200 (step S04). The image processing unit 210 of the image processing device 200 then performs image processing (correction) on the painting image data to eliminate the deviations in the paint landing positions, and as a result, creates corrected painting data C1 as shown in Fig. 8 (step S05). In the corrected painting data C1 shown in Fig. 8, correction (image processing) is performed on the painting image data so as to impart vibrations of opposite phase to the vibrations that are affecting the measured image data D1.

[0058] Here, when the measurement image data D1 is acquired by scanning the measurement image S1, it is considered that a positional deviation of +x1 occurs at a predetermined position P1 of the measurement image S1 due to the influence of vibration (see FIG. 7). In this case, it is considered to form a coating part having the same shape as the measurement image S1. In this case, in the correction coating data C1, a process is performed to shift the position by -x1 to eliminate the positional deviation of +x1 at the above-mentioned predetermined position P1. In other words, the correction coating data C1 for coating is created by applying vibration of the opposite phase to the vibration occurring in the measurement image data D1.

[0059] The corrective coating data C1 created as described above is sent from the image processing device 200 to the main control unit 100, and the corrective coating data C1 is stored in the memory 101 (step S06). In the coating robot 10, the robot arm control unit 70 controls the operation of the robot arm R1 in response to a command from the main control unit 100 so as to move the coating head 53 to a predetermined position where coating is to be performed. In addition, in response to a command from the main control unit 100, the paint supply control unit 80 ejects droplets from the nozzle 54 based on the corrective coating data C1. In other words, coating is performed on the coating area (step S10).

[0060] As described above, even if the correction coating data C1 is created, positional deviation may occur. In other words, in normal coating where the influence of vibration is not taken into consideration, the accuracy of the landing position of the droplets can be improved by measurement with the position sensor 120, etc. However, when vibration is present, even if droplets are to be landed at the same position, a positional deviation of +x1 occurs at time t1 when the vibration amplitude is +x1, and a positional deviation of -x2 occurs at another time t2 when the vibration amplitude is -x2, and so the position cannot be determined only by measurement with the position sensor 120, etc.

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

[0062] Therefore, when actually performing painting, the following procedure may be adopted. That is, when starting painting, the painting head 53 is made to wait at a predetermined waiting position (step S07). Then, while the painting head 53 is in this waiting state at the waiting position, a sensor such as the tilt sensor 130 (or the vibration sensor 150 if a vibration sensor 150 is present) measures the vibration state of the painting head 53 (step S08).

[0063] In the vibration measurement, when the vibration of the paint head 53 reaches a predetermined phase, the robot arm control unit 70 actuates the robot arm R1 to move the paint head 53 to the painting site (step S09). In this way, the effect of vibration is supposed to be eliminated in painting with the paint head 53, but instead, the effect of vibration is amplified, which can be suppressed.

[0064] In the vibration measurement in step S08, it is preferable to adjust the moving speed of the paint head 53 based on the frequency measured in the vibration state measurement in step S08. When adjusting the moving speed of the paint head 53 in this manner, it is possible to prevent the phase of the correction paint data C1, which is created to be in opposite phase to the vibration state of the paint head 53, from being shifted.

[0065] Furthermore, it is rare for the paint head 53 to vibrate only along the x-direction, which is the sub-scanning direction, and its vibration equation typically has x-, y-, and z-direction components in the three-dimensional space of xyz.

[0066] Therefore, when creating the corrective coating data C1 so as to impart vibrations of opposite phase to the vibrations occurring in the measured image data D1, it is preferable to perform correction (image processing) of the measured image data D1 so as to impart vibrations of opposite phase to the vibrations in each direction, not only in the x-direction component but also in the y-direction component and the z-direction component, to create the corrective coating data C1. In this way, by creating the corrective coating data C1 so as to impart vibrations of opposite phase to the vibrations in the x-direction, y-direction, and z-direction occurring 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 in the z-direction, which is the thickness direction.

[0067] Furthermore, when the vibration state of the paint head 53 extends to the edge of the part to be painted, if painting data for ejecting droplets from all nozzles 54 is created during normal painting without vibration, it may be impossible to eliminate the vibration state of the paint head 53. This is because the vibration of the paint head 53 may result in a situation where the nozzles 54 are not present (not positioned) at the part that should be painted.

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

[0069] In image processing by the image processing device 200 (image processing section 210), when the painting head 53 is not vibrating, the edge E1a of the painting data E1, which is data for painting the part to be painted, is not in contact with the correction nozzle 54C. Also, the 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 the vibration can be absorbed by the correction nozzle 54C.

[0070] (3. Modifications) Although one embodiment of the present invention has been described above, the present invention can be modified in various ways in addition to the above embodiment. Modifications will be described below.

[0071] In the above embodiment, a case where a three-dimensional scanner 140 is used as the image acquisition means is described. However, the image acquisition means is not limited to the three-dimensional scanner 140. For example, a two-dimensional 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, when the three-dimensional scanner 140 is configured to be able to acquire three-dimensional data by combining multiple ordinary cameras capable of acquiring two-dimensional data, for example, the combination of these multiple cameras corresponds to the three-dimensional scanner 140 of the present invention.

[0073] In the above embodiment, it may be assumed that the vibration state of the paint head 53 has changed due to some abnormal cause, such as the occurrence of abnormal motor vibration. In this case, when new measured image data D1 as shown in Fig. 7 is acquired, the new measured image data D1 can be compared with previously acquired measured image data D1 and used to detect an abnormality.

[0074] In the above embodiment, when the newly acquired measured image data D1 is analyzed, it is possible to detect abnormal values ​​such as a clearly large amplitude when compared with the previously acquired measured image data D1. The detection of such abnormal values ​​may be used to detect abnormalities, such as by having the painting robot 10 issue an alert, or the painting may be stopped upon detection of the abnormality. This may avoid painting in an abnormal state and increase the probability of success in painting using the correction painting data C1.

[0075] (4. Notes) 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 portion of a vehicle, A paint head unit 50 including a paint head 53 having a plurality of nozzles 54 for ejecting paint droplets; a robot arm R1 having a painting head unit 50 attached to its tip and moving the painting head unit 50 to a desired position; A three-dimensional scanner 140 (image acquisition means) for acquiring painting data of a part painted by the painting head 53; and 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 three-dimensional scanner 140 (image acquisition means) and also controls the operation of the painting head 53 and the robot arm R1. The control unit (main control unit 100, robot arm control unit 70, head control unit 90, main control unit 100) Activating the three-dimensional scanner 140 (image acquisition means) and scanning the measurement image S1 with the three-dimensional scanner 140 (image acquisition means) before painting is performed to acquire measurement image data D1 reflecting the vibration state of the three-dimensional scanner 140 (image acquisition means); Based on the measured image data D1 acquired by the three-dimensional scanner 140 (image acquisition means), correction coating data C1 is created to eliminate deviations in the landing positions of the droplets discharged from the coating head 53; Based on the corrective painting data C1, the robot arm R1 and the painting head 53 are controlled to be driven.

[0076] In this way, by creating correction coating data C1 that aims to eliminate deviations in landing positions based on the vibration state (fluctuation) measured by the three-dimensional scanner 140 (image acquisition means), it becomes possible to eliminate deviations in landing positions of droplets ejected from the coating head 53. This makes it possible to perform high-definition coating without the effects of the vibration state (fluctuation).

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

[0078] In this way, by using the three-dimensional scanner 140 as the image acquisition means and creating the correction coating data C1 based on the measurement of the measurement image S1 by the three-dimensional scanner 140, it becomes possible to eliminate not only the deviation of the landing position of the droplets in the planar direction of the coating part, but also the deviation of the landing position of the droplets in the thickness direction of the coating part. Therefore, it becomes possible to perform high-definition coating in which the effects of the vibration state (fluctuation) are eliminated three-dimensionally.

[0079] [3] In addition to the above-mentioned [1] and [2], or a combination thereof, in the above-mentioned embodiment, The three-dimensional 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 paint head 53, it becomes possible to measure with high accuracy the vibration state of the paint head 53. This makes it possible to predict with high accuracy the deviation of the landing position due to the vibration state (fluctuation), and enables high-definition painting that eliminates the effects of fluctuation.

[0081] [4] In addition to the above-mentioned embodiments, in addition to any of the above-mentioned [1] to [3] or a combination thereof, The control unit (main control unit 100, robot arm control unit 70, head control unit 90, scanner control unit 110) may create the corrective coating data in an opposite phase to the vibration state.

[0082] In this way, by creating the correction painting data C1 in the opposite phase to the vibration state, the effects of the vibration state (fluctuation) are eliminated, making it possible to perform high-precision painting.

[0083] [5] In addition to the above-mentioned embodiments, in addition to any of the above-mentioned [1] to [4] or a combination thereof, When the influence of the vibration state extends to the edge of the coating area, the nozzles 54 on the nozzle forming surface 52 of the coating head 53 are determined to be correction nozzles 54C within a predetermined range from the end of the coating head 53 in the sub-scanning direction, and the nozzles 54 located closer to the center of the coating head 53 than the predetermined range are determined to be normal coating nozzles 54N. The control unit (main control unit 100, robot arm control unit 70, head control unit 90, scanner control unit 110) When the painting head 53 is not in a vibrating state, the edge of the painting data, which is data for painting the painting area, is not in contact with the correction nozzle 54C. The correcting coating data C1 may be created so that the vibrations at the edges of the coating data are absorbed by the correcting nozzle 54C.

[0084] By painting in this manner, the painting area is painted by ejecting droplets from the normal painting nozzle 54N, but by using the outer nozzle 54 as the correction nozzle 54C to paint, when the painting head 53 vibrates, the amplitude of the vibration can be absorbed by the correction nozzle 54C. This makes it possible to effectively eliminate the effects of deviations in the landing positions of the droplets. [Explanation of symbols]

[0085] 1...painting system, 10...painting robot, 20...robot body, 21...base, 22a...first rotating shaft, 22b...second rotating shaft, 22c...third rotating shaft, 22d...fourth rotating shaft, 22e...fifth rotating shaft, 22f...sixth rotating shaft, 23...leg, 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 a part of the control unit), 71...memory, 80...paint supply control unit, 90...head control unit (corresponding to a part of the control unit), 100...main control unit (corresponding to a part of the control unit), 101...memory, 110...scanner control unit (corresponding to a part of the control unit), 120...position sensor, 130...tilt sensor, 140...3D scanner, 150...vibration sensor, 200...image processing device, 210...image processing unit, 220...memory, C1...painting data for correction, D1...measurement image data, D1a...edge, E1...painting data, E1a...edge, M1 to M6...motor, R1...robot arm, S1...measurement image, S1a...edge

Claims

1. A painting system including a painting robot that paints a part of a vehicle, a paint head unit including a paint head having a plurality of nozzles for ejecting paint droplets; a robot arm having a tip end to which the 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 a portion painted by the painting head; A control unit that controls the operation of the image acquisition means and controls the operation of the painting head and the robot arm, The control unit is Activating the image acquisition means, scanning a measurement image with the image acquisition means before painting is performed, and acquiring measurement image data reflecting a vibration state of the image acquisition means; creating correction coating data for eliminating deviations in landing positions of droplets discharged from the coating head based on the measured image data acquired by the image acquisition means; and executing drive control of the robot arm and the painting head based on the corrective painting data. A coating system characterized by:

2. 2. The coating system of claim 1, the image acquisition means is a three-dimensional scanner that acquires three-dimensional painting data of the painting area; the control unit creates the correction painting data for eliminating the deviation of the landing position in a thickness direction of the coating area as well as the deviation of the landing position in a planar direction of the coating area based on the measurement of the measurement image before the coating is performed. A coating system characterized by:

3. 2. The coating system of claim 1, The image acquisition means is fixed to the painting head. A coating system characterized by:

4. 2. The coating system of claim 1, The control unit creates the correction painting data in an opposite phase to the vibration state. A coating system characterized by:

5. 2. The coating system of claim 1, when the influence of the vibration state extends to an edge of a coating portion, among the range of nozzles on the nozzle forming surface of the coating head, the nozzles within a predetermined range from an end of the coating head in the sub-scanning direction are defined as correction nozzles, and the nozzles located closer to the center of the coating head than the predetermined range are defined as normal coating nozzles; The control unit is When the painting head is not in the vibration state, an edge of painting data, which is data for painting the painting area, is not in contact with the correction nozzle, creating the correction coating data so that the correction nozzle absorbs vibrations at the edges of the coating data; A coating system characterized by:

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