Spraying method

Abstract

To provide a spray construction method improving efficiency of operation relating to a spray construction including check on spray thickness on a construction objective surface after spray operation.SOLUTION: A spray construction method includes: a pre-measurement step of measuring a distance to a construction objective surface at a plurality of measurement points previously set on the construction objective surface as moving distance measurement means along the construction objective surface before spray operation; a post-measurement step of measuring a distance to the construction objective surface as moving the distance measurement means along the route where the distance measurement means have been moved after the spray operation on the construction objective surface; and a spray thickness check step of checking spray thickness based on pre-spray distance measured values acquired through the pre-measurement step and post-spray distance measured values acquired through the post-measurement step.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to spraying construction including an operation of checking the spraying thickness on the construction target surface after the spraying operation. Spraying method It relates to.

Background Art

[0002] For steel frame structures, fireproof coating work is carried out to make them fireproof structures by coating the surface of the structure with a fireproof coating material, for example, by spraying. The spraying operation of the fireproof coating material is carried out by skilled on-site workers, but in recent years, various spraying devices have been developed in order to achieve labor saving.

[0003] For example, Patent Document 1 discloses a spraying construction device provided with a discharging means for discharging a fireproof coating material on a support provided with a lifting mechanism and a traversing mechanism, and distance sensors are provided on the front side and the rear side in the moving direction of the nozzle constituting the discharging means. When performing the fireproof coating work, the spraying operation of the fireproof coating material and the distance measurement work to the construction surface by two distance sensors are carried out simultaneously, and the distance to the construction surface before the nozzle passes and the distance to the construction surface after the nozzle passes are measured.

[0004] According to the above spraying construction device, it is possible to check the spraying thickness due to the nozzle passing through the construction target surface once. Thereby, the unit discharge amount of the fireproof coating material is adjusted by increasing or decreasing the moving speed of the nozzle based on the spraying thickness, or by increasing or decreasing the supply amount of the fireproof coating material to the nozzle, etc., aiming to improve the construction efficiency and ensure stable construction quality.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] By the way, in refractory coating work, after the spraying work is completed, quality control for checking the spraying thickness of the refractory coating material on the construction target surface is mandatory. Generally, in the confirmation work, thickness confirmation pins are inserted into the refractory coating material on the construction target surface, and field workers confirm that the spraying thickness meets the specified thickness.

[0007] Therefore, even if a spraying construction device capable of improving construction efficiency is adopted during the spraying work, manpower is required during the work of checking the spraying thickness. Furthermore, when the construction target surface is at a high place, high-altitude work using a work scaffold, an aerial work platform, etc. will occur.

[0008] Under such circumstances, it is also conceivable to adopt the spraying thickness that can be obtained by the spraying construction device of Patent Document 1 for quality control. However, the obtainable spraying thickness is the spraying thickness when the nozzle passes through the construction target surface once. Therefore, when a method of finishing the refractory coating by spraying the refractory coating material repeatedly is adopted, in order to grasp the spraying thickness after the spraying work, a calculation process such as accumulating the spraying thickness each time the nozzle passes through a measurement point and adding them together is required, and the quality control work tends to become complicated.

[0009] Also, even in the method of finishing the refractory coating by one spraying operation on the construction target surface, since the nozzle and two distance sensors move simultaneously, when the desired measurement point on the construction target surface is not on the movement path of the nozzle, the spraying thickness cannot be confirmed. Furthermore, since two distance sensors are installed adjacent to the nozzle, if the sprayed refractory coating material scatters and adheres to the distance sensors, there is a risk that accurate distance measurement cannot be performed.

[0010] The present invention has been made in view of such problems, and its main object is to improve the efficiency of work related to spraying construction, including the work of checking the spraying thickness on the construction target surface after the spraying work.

Means for Solving the Problems

[0011] To achieve the above object, the spraying method of the present invention is as follows: A spraying method for spraying a refractory coating material made of a material containing rock wool granular cotton and a cement-based hardening material onto a construction target surface of a building, Before the spraying operation, while moving the distance measuring means along the construction target surface, a pre-measurement step of measuring the distance from the construction target surface at a plurality of measurement points set in advance on the construction target surface is performed. After the spraying operation is carried out on the construction target surface, a post-measurement step of measuring the distance from the construction target surface is performed while moving the distance measuring means along the path moved in the pre-measurement step. Based on the pre-spraying distance measured value obtained in the pre-measurement step and the post-spraying distance measured value obtained in the post-measurement step, a spraying thickness confirmation step of confirming the spraying thickness is provided. The post-measurement step is carried out after the spraying operation and before performing a refractory finish that presses the surface of the sprayed refractory coating material. In the spraying thickness confirmation step, it is confirmed whether the difference between the measured value of the distance before spraying and the measured value of the distance after spraying satisfies the thickness obtained by adding the specified thickness and the allowance considering the reduction in bulk due to the refractory finish. It is characterized by the above. Also, The construction target surface is a beam member, and the distance measurement from the construction target surface is carried out using distance measurement means connected to the spraying body of spraying means including a cylindrical spraying body and a gun head provided at the tip thereof for spraying a refractory coating material. The spraying means is provided on a robot arm mounted on a traveling section. The traveling section includes a base section that supports the robot arm, a lifting device that raises and lowers the robot arm, a traversing device that continuously moves the robot arm in at least a direction along the construction target surface on the traveling section, and a traveling carriage that supports the lifting device and the traversing device. The traversing device has a traveling gantry and a frame on which the traveling gantry moves. The base section is installed on the traveling gantry and supports the robot arm rotatably within the upper surface while moving on the frame. It is characterized by the above.

[0014] The present invention of According to the spraying method, the distance from the construction target surface is measured while moving the distance measuring means along the same path along the construction target surface before and after the spraying operation. Thereby, even when a plurality of measurement points are provided on the construction target surface, the distance measurement operation can be carried out with high reproducibility at each measurement point, and the pre-spraying distance measured value and the post-spraying distance measured value can be obtained.

[0015] Therefore, it is possible to efficiently obtain the spraying thickness based on the pre-spraying distance measured value and the post-spraying distance measured value without the need for complicated operations such as using special jigs or performing complicated data processing. Also, since the pre-measurement step and the post-measurement step related to distance measurement are carried out in a process separate from the spraying operation, the distance measuring means can be moved in a suitable posture, and the distance measurement operation can be carried out while ensuring high accuracy at the desired measurement points on the construction target surface. Thereby, it is possible to obtain a highly reliable spraying thickness.

Effect of the Invention

[0016] According to the present invention, since the distance measurement by the distance measuring means with respect to the construction target surface is performed before and after the spraying operation to confirm the spraying thickness, it is possible to improve the efficiency of the operations related to the spraying construction, including the operation of confirming the spraying thickness on the construction target surface.

Brief Description of the Drawings

[0017]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Embodiments for Carrying Out the Invention

[0018] The spraying method, program, and spraying construction system of the present invention will be described below with reference to FIGS. 1 to 9 by taking as an example the case of performing the spraying construction of a fireproof coating material including rock wool on a construction target surface of a building.

[0019] ≪≪Spraying Construction of Fireproof Coating Material≫≫ As shown in Fig. 1, for the spraying construction of the fireproof coating material C, first, the fireproof coating material C made of a material containing rock wool granular cotton and a cement-based hardening material is sprayed onto the construction target surface 101a of the building 100. Next, fireproof finishing is performed by means such as so-called trowel pressing to suppress the fluffing occurring on the surface of the sprayed fireproof coating material C.

[0020] After that, the thickness of the fireproof coating material C is measured on the construction target surface 101a where the fireproof finishing has been performed. Such a thickness confirmation operation after spraying is obligatorily carried out at one or more locations for every 5 m 2 of the spraying area. Therefore, the larger the construction target surface 101a is, the greater the number of measurement points will be.

[0021] Therefore, as shown in Fig. 2, not only the spraying means 1 but also the non-contact distance measuring means 2 are provided on the robot arm A of the spraying construction system 10 that realizes the automation of the spraying operation, aiming to automate the operation of confirming the spraying thickness on the construction target surface 101a after spraying. The general procedure is as follows. In this embodiment, the case where the construction target surface 101a is provided on the surface of the beam member 101 constituting the building 100 is taken as an example.

[0022] First, as shown in Fig. 3(a), before performing the spraying operation of the fireproof coating material C, the distance from the arrangement position of the distance measuring means 2 to the construction target surface 101a is measured, and the pre-spraying distance measured value D1 is obtained. When performing the distance measurement, measurement locations serving as a guide for the distance measurement position are set at predetermined positions on the construction target surface 101a. In this embodiment, measurement lines R1 to R7 are prepared as the distance measurement positions.

[0023] Fig. 4(a) shows the positions of measurement lines R1 to R7 as seen from the cross-section of the beam member 101, all of which are set as parallel straight lines extending in the longitudinal direction of the beam member 101. Note that the measurement line R1 is set on the lower surface of the upper flange of the beam member 101, the measurement lines R2 and R3 are set on the web, and the measurement line R4 is set on the upper surface of the lower flange. Also, the measurement line R5 is set at the small end of the lower flange, and the measurement lines R6 and R7 are set on the lower surface of the lower flange respectively. The distance measuring means 2 is moved along a continuous one-stroke movement path Tr as shown in Fig. 4(b) for example, which enables continuous measurement of these measurement lines R1 to R7.

[0024] Next, as shown in Fig. 3(b), spraying work is carried out on the construction target surface 101a using the spraying means 1. The spraying means 1 is moved along a one-stroke movement path set to spray the fireproof coating material C onto the construction target surface 101a homogeneously and to consider the reduction in bulk due to trowel pressing, so that the thickness is greater than the specification thickness S1.

[0025] Thus, since the distance measurement work and the spraying work are carried out in separate processes, the distance measuring means 2 during the distance measurement work and the spraying means 1 during the spraying work can be moved along different movement paths suitable for each work. Also, the moving speed and posture of the spraying means 1 and the distance measuring means 2 can be set in a suitable manner corresponding to each work.

[0026] After that, as shown in Fig. 3(c), the distance from the arrangement position of the distance measuring means 2 to the construction target surface 101a is measured to obtain the measured distance value D2 after spraying. The distance measuring means 2 is moved along the movement path Tr adopted when the measured distance value D1 before spraying was obtained. Thereby, the distance measuring means 2 can measure the distance to the construction target surface 101a along the measurement lines R1 to R7 at the same position and in the same posture before and after the spraying work.

[0027] Thus, based on the measured value D1 of the distance before spraying and the measured value D2 of the distance after spraying obtained before and after the spraying operation, the measured value D of the thickness of the refractory coating material C sprayed on the construction target surface 101a is calculated. Note that the distance measurement by the distance measurement means 2 may be continuously measured along each of the measurement lines R1 to R7, or may be intermittently measured at predetermined intervals. Further, the trowel presser may be performed at any timing before or after the distance measurement operation performed after the spraying operation.

[0028] The above operation of measuring the distance to the construction target surface 101a continuously or intermittently while moving the distance measurement means 2 along the same movement path Tr before and after the spraying operation in a process separate from the spraying operation can be realized by using a robot arm A capable of reproducing the same operation. Hereinafter, the details of the spraying construction system 10 used for the spraying construction performed by the above procedure will be described.

[0029] ≪≪Spraying Construction System≫≫ As shown in FIG. 2, the spraying construction system 10 includes a robot arm A provided with a spraying means 1 and a distance measurement means 2, a traveling unit B mounted with the robot arm A, and a spraying management device 9 for managing the spraying construction.

[0030] ≪Spraying Means and Distance Measurement Means≫ The spraying means 1 includes a cylindrical spraying main body 11, a gun head 12 provided at the tip thereof for injecting the refractory coating material C, and a connecting portion 13 for connecting the spraying main body 11 and a supply hose for supplying the refractory coating material C.

[0031] The distance measurement means 2 includes a distance meter 21 disposed adjacent to the spraying means 1 and a connecting jig 22 for connecting the distance meter 21 to the spraying main body 11. As the distance meter 21, a laser distance sensor is adopted, and the laser light L emitted from the laser emitting portion 23 and the injection direction of the refractory coating material C injected from the gun head 12 are arranged to be parallel.

[0032] In addition, a protective cap 24 is detachably attached to the laser light emitting unit 23. This is provided to prevent the refractory coating material C from adhering to the laser light emitting unit 23 during the spraying of the refractory coating material C from the gun head 12 of the spraying means 1. Therefore, when using a spraying material that does not cause splashing or the like, the protective cap 24 does not necessarily have to be provided. Further, the opening and closing operation of the protective cap 24 may be manual by an operator, or may be configured to automatically perform the opening and closing operation using power.

[0033] Note that the laser distance sensor employed in the distance measuring device 21 is, for example, a self-position estimating type optical position measuring sensor such as a laser scanner, which scans the laser beam L on the measurement target surface and measures the distance to the measurement target surface while receiving the reflected laser beam. Also, the distance measuring device 21 may be any sensor that can measure the distance to an object non-contact, and for example, an ultrasonic sensor or the like may be employed.

[0034] ≪Robot Arm≫ The robot arm A includes a multi-joint structure manipulator 3 provided with the above-described spraying means 1 and distance measuring means 2 as end effectors at the tip portion. In the present embodiment, a 6-axis multi-joint robot is employed, which operates based on a job file described later and controls the operations of the spraying means 1 and the distance measuring means 2 by its operation.

[0035] In the present embodiment, the robot arm A is constructed such that the axis of the gun head 12 of the spraying means 1 coincides with the axis of the manipulator 3. Therefore, the distance measuring device 21 connected to the spraying means 1 via the connection jig 22 is arranged in a state where the emitted laser beam L is eccentric with respect to the axis of the manipulator 3.

[0036] ≪Traveling Unit≫ The traveling unit B includes a base portion 4 that supports the robot arm A, a traversing device 5, a traveling carriage 6, and a lifting device 7. The base portion 4 is installed so as to be movable along the longitudinal direction on the traversing device 5, and rotatably supports the robot arm A within the upper surface.

[0037] The traversing device 5 includes a long frame 51 and a traveling gantry 52 that is movable along the longitudinal direction of the frame 51, and the aforementioned base portion 4 is installed on this traveling gantry 52. The traveling gantry 52 may be configured to move on the frame 51 by any means. For example, a roller chain, a sprocket, and a motor connected to the traveling gantry 52 may be built into the frame 51, and the traveling gantry 52 may be moved according to the rotation of the roller chain.

[0038] The traveling carriage 6 has a structure that can travel on the floor surface of the building 100, and includes a rectangular top plate 61 on which the aforementioned traversing device 5 is placed and a carriage body 62. Further, it includes traveling means 63 and an outrigger device 64 installed on the lower surface of the carriage body 62. The traveling means 63 employs mecanum wheels that can move in all directions, but is not necessarily limited to this. As long as the traveling carriage 6 can move in all directions, for example, any of omnidirectional rollers or the like may be employed.

[0039] With respect to the traveling carriage 6 having such a configuration, the traversing device 5 passes through the center of gravity of the traveling carriage 6 in plan view, and the longitudinal direction thereof, that is, the moving direction of the base portion 4 that supports the robot arm A, is arranged to be parallel to the traveling direction of the traveling carriage 6. And the center of gravity of the traveling unit B in plan view is set as the home position P of the robot arm A.

[0040] Also, a lifting device 7 is interposed between the rectangular top plate 61 and the carriage body 62 of the traveling carriage 6. Any lifting device 7 may be used as long as it has a telescopic mechanism capable of pushing up the rectangular top plate 61. In the present embodiment, a pantograph jack is employed.

[0041] Furthermore, the traveling unit B is provided with a self-position detection sensor 81 for grasping the planar position and traveling direction, a height detection sensor 82 for grasping the height position of the base unit 4, and an attitude detection sensor 83 for grasping the attitude angles (roll, pitch) of the traveling unit B.

[0042] The self-position detection sensor 81 is an optical position measurement sensor unit of the self-position estimation type such as a laser scanner, and is installed on the carriage body 62 of the traveling carriage 6. The planar position and traveling direction of the traveling carriage 6 using the self-position detection sensor 81 are calculated based on, for example, BIM data. Note that the BIM data stores design information such as design drawings of the building 100, and is data used to reproduce a three-dimensional model of the same building 100 as the actual one on a computer.

[0043] The height detection sensor 82 is a stroke sensor installed on the rectangular top plate 61 and the carriage body 62 to measure the expansion and contraction amount of the lifting device 7, and is provided on the lifting device 7. The attitude detection sensor 83 is an inclinometer used to measure the attitude angles (roll, pitch) of the traveling unit B with respect to the floor surface, and is installed on the base unit 4.

[0044] ≪Spraying Management Device≫ The spraying management device 9 is installed on the carriage body 62 of the traveling carriage 6, and includes at least an arithmetic processing device 91, an input unit 92, an output unit 93, a storage unit 94, and a communication unit 95 as shown in FIG. 5. The communication unit 95 will be described later.

[0045] The output unit 93 is composed of, for example, a flat panel display such as a liquid crystal display or an organic EL display, and has a function of displaying the information input by the input unit 92 and the information stored in the storage unit 94. The input unit 92 includes a keyboard having cursor keys, numeric input keys, and various function keys, a pointing device such as a mouse, etc., receives operation signals input by key operations, mouse operations, etc., and outputs them to the storage unit 94 and the arithmetic processing device 91.

[0046] It is preferable to adopt an integrated configuration for these output unit 93 and input unit 92, such as a flat panel display with a touch panel. Further, the storage unit 94 is a storage device composed of a semiconductor memory, a hard disk drive, or the like. Although details will be described later, it includes at least a data file 941, a measurement job file 942, a spraying job file 943, a re-spraying job file 944, and a thickness confirmation file 945.

[0047] The arithmetic processing unit 91 includes a CPU, a GPU, a ROM, a RAM, a hardware interface, etc., and by executing a predetermined program, the functions of an installation control unit 911 and a job file modification unit 912, which will be described later, are realized. Further, the functions of a robot arm control unit 913, a robot arm position movement control unit 914, and a spraying thickness confirmation unit 915 are realized.

[0048] As shown in FIG. 6, the installation control unit 911 has a function of positioning the traveling unit B that has traveled from the robot station S installed indoors in the building 100 toward the target position G set near the construction target surface 101a within an allowable range centered on the target position G.

[0049] When it is necessary to correct job files such as the measurement job file 942, the spraying job file 943, and the re-spraying job file 944 stored in the storage unit 94, the job file modification unit 912 has a function of rewriting and correcting these descriptions based on the correction information.

[0050] The robot arm control unit 913 has a function of controlling the operation of the manipulator 3 based on the above job file. Further, the robot arm position movement control unit 914 has a function of controlling the operations of the traversing device 5 and the lifting device 7 to move the horizontal position and the height position of the base unit 4 that supports the manipulator 3.

[0051] And the spraying thickness confirmation unit 915 has a function of calculating the measured thickness D of the refractory coating material C sprayed on the construction target surface 101a as shown in Fig. 3(c) based on the measured value D1 of the distance before spraying and the measured value D2 of the distance after spraying measured before and after the spraying operation. It also has a function of confirming that the measured thickness D satisfies the reference value S of the preset spraying thickness.

[0052] If the spraying management device 9 has the above functions, a notebook PC, a tablet terminal, a smartphone, etc. can be adopted.

[0053] ≪≪Spraying method using the spraying construction system≫≫ The procedure of the operation of confirming the spraying thickness of the construction target surface 101a after the spraying operation, including the spraying operation of the refractory coating material C and the distance measurement operation to the construction target surface 101a performed before and after the spraying operation, which is carried out using the above spraying construction system 10, will be described below along the spraying construction flow shown in Fig. 7 in conjunction with the details of the spraying management device 9 shown in Fig. 5.

[0054] In this embodiment, a case is cited where the construction target surface 101a is divided into a plurality of work sections, and the distance measurement operation after the spraying operation is carried out before the trowel pressing.

[0055] ≪≪Pretreatment process: Step1≫≫ First, as shown in Fig. 6, a plurality of work sections are set on the construction target surface 101a of the beam member 101. The size of the work section is set in consideration of the operable range of the manipulator 3 and the movable range of the base portion 4. That is, it is set within a range where the spraying construction system 10 after being installed at the target position G can perform the spraying operation and the distance measurement operation without moving the traveling section B.

[0056] When performing the spraying operation and the distance measurement operation, the lateral movement of the spraying means 1 is controlled by the operation of the manipulator 3 and the movement on the traversing device 5 of the base portion 4. Also, the vertical movement is controlled by the operation of the manipulator 3 and the raising and lowering of the elevating device 7 provided on the traveling carriage 6. Considering these, for example, in FIG. 6, the construction target surface 101a is divided into two work sections E1 and E2.

[0057] Next, for each of the work sections E1 and E2, target positions G1 and G2 (targets for the planar view position (planar center of gravity position) of the traveling section B) that are the stop targets of the spraying construction system 10 traveling from the robot station S are set. Also, when installing the spraying construction system 10, the target direction in the traveling direction, the target attitude angle, and the target height of the base portion 4 are set, and respective allowable values are set. All of these are stored in the data file of the storage unit 94 in the spraying management device 9.

[0058] Furthermore, for each of the work sections E1 and E2, a spraying job file 943 and a measurement job file 942 are prepared. In the spraying job file 943, information including the movement path and posture of the spraying means 1 based on the operation of the manipulator 3 (such as the discharge direction of the refractory coating material C discharged from the gun head 12) is described in parameters and numerical values.

[0059] Also, in the measurement job file 942, information including the movement path and posture of the distance measurement means 2 based on the operation of the manipulator 3 (such as the emission direction of the laser light L emitted from the laser emission unit 23) is described in parameters and numerical values. These spraying job files and measurement job files are stored in the storage unit 94 in the spraying management device 9.

[0060] In addition, when it is necessary to move the base unit 4 in the horizontal and height directions along with the operation of the manipulator 3 for each work section E1 and E2, movement information of the base unit 4 is prepared as information for controlling the operations of the lateral movement device 5 and the elevating device 7. The movement information of the base unit 4 is stored in a data file in the storage unit 94 of the spraying management device 9. Note that if the movement information of the base unit 4 is different between the distance measurement work and the spraying work, it is prepared separately.

[0061] Then, a reference value S for the spraying thickness used when checking the spraying thickness on the construction target surface 101a after the spraying work is set. When the distance measurement after the spraying work is carried out after pressing with a trowel, the reference value S for the spraying thickness is set to the same quantity as the specified thickness S1. On the other hand, when the distance measurement after the spraying work is carried out before pressing with a trowel, it is set to the quantity obtained by adding the specified thickness S1 and the allowance S2. These are created for each work section E1 and E2 and stored in the storage unit 94 of the spraying management device 9.

[0062] ≪≪Installation process: Step2≫≫ After finishing the preprocessing process of Step1, in order to start the spraying work and the distance measurement work in the work section E1, the spraying construction system 10 is moved toward the target position G1 and installed. The details of the spraying construction system 10 including the above-described configuration are referred to Japanese Patent Application Laid-Open No. 2020-20206, and its outline is as follows.

[0063] ≪Movement and installation work of the spraying construction system≫ As shown in FIGS. 2 and 6, the spraying construction system 10 is parked at the robot station S of the building 100 with the robot arm A positioned at the home position P. From this state, the spraying construction system 10 is run while measuring the planar position and the traveling direction related to the center of gravity of the traveling unit B using the self-position detection sensor 81.

[0064] When approaching near the target position G1, the spraying construction system 10 is moved to a preset target orientation, and the traveling unit B is temporarily stopped. The target orientation when the spraying construction system 10 stops is the direction in which the robot arm A can move along the construction target surface 101a on the traversing device 5, that is, the orientation in which the traversing device 5 is parallel to the construction target surface 101a.

[0065] After that, when starting the operation of the traveling unit B, the arithmetic processing unit 91 of the spraying management device 9 receives the command of the installation control unit 911, and measures the position and traveling direction of the center of gravity of the traveling unit B in plan view, and the differences between the target position G1 and the target orientation stored in the data file of the storage unit 94. It is verified whether these are within the allowable value range. If they are within the range, the traveling unit B is positioned at that position, and the traveling unit B is installed via the outrigger device 64.

[0066] In conjunction with these operations, the difference between the height position of the base unit 4 due to the lifting operation of the lifting device 7 and the target height stored in the data file of the storage unit 94 is measured, and the difference between the height position and the target height is detected. When this difference is within the allowable value range, the height adjustment operation is stopped.

[0067] Also, the difference between the measured values of the attitude angles (roll, pitch) of the traveling unit B and the target attitude angles stored in the data file of the storage unit 94 is measured and stored in the data file of the storage unit 94. In addition, the differences between the center-of-gravity position and traveling direction of the installed traveling unit B in plan view and the target position G and the target orientation, and the difference between the measured value related to the height of the base unit 4 and the target height are also stored in the data file of the storage unit 94 in the same manner.

[0068] ≪Preparation Work for Spraying Process≫ As described above, both the spraying job file 943 and the measurement job file 942 describe parameters and numerical values for controlling the operation of the manipulator 3 starting from the home position P of the robot arm A as shown in FIG. 2. Therefore, if there is a discrepancy in the position of the home position P at the time of creating these job files and the time of installing the traveling unit B, the arithmetic processing unit 91 receives a command from the job file correction unit 912 and corrects the above job files.

[0069] ≪≪Measurement and Spraying Process: Step3≫≫ As described above, when the installation of the spraying construction system 10 and the correction of the spraying job file and the measurement job file are completed, the spraying operation on the construction target surface 101a in the work section E1 and the distance measurement operation for confirming the thickness of the refractory coating material C are started.

[0070] ≪Distance Measurement Operation before Spraying Operation (Pre-measurement Process: Step3-1)≫ The arithmetic processing unit 91 receives a command from the robot arm control unit 913, operates the manipulator 3 based on the measurement job file 942, and starts the distance measurement operation by the distance measurement means 2 as shown in FIG. 3(a). Also, receiving a command from the robot arm position movement control unit 914, the traversing device 5 and the lifting device 7 are operated based on the movement information of the base unit 4, and the base unit 4 is moved in the horizontal direction and the height direction.

[0071] Thereby, as shown in FIG. 8(a), the distance measurement means 2 moves along the longitudinal forward path of the beam member 101 so that the laser beam L irradiates the lower surface of the upper flange along the measurement line R1. Next, as shown in FIG. 8(b), the distance measurement means 2 moves along the return path so that the laser beam L irradiates the web along the measurement line R2.

[0072] In this way, while the distance measuring means 2 reciprocates in the longitudinal direction of the beam member 101 along the movement path Tr as shown in Fig. 4(b), the distance measurement operation is performed while sequentially facing the direction of the laser light emitting unit 23 toward the measurement lines R1 to R7. As a result, the pre-spraying distance measured value D1 can be continuously measured in a single stroke along the measurement lines R1, R2,... as shown in Fig. 8(c). Note that the pre-spraying distance measured value D1 may be continuously acquired along the measurement lines R1 to R7, or may be acquired for each measurement point M set in advance.

[0073] The pre-spraying distance measured value D1 acquired by the distance measuring means 2 is sequentially stored in the thickness confirmation file 945 provided in the storage unit 94 of the spraying management device 9 after being associated with the position information of the measured position. Note that the distance measuring means 2 is preferably connected to the spraying management device 9 so as to be communicable wirelessly or by wire.

[0074] ≪Spraying operation: Step3-2≫ After the pre-spraying distance measured value D1 is stored in the storage unit 94, the arithmetic processing unit 91 receives a command from the robot arm control unit 913 and operates the manipulator 3 based on the spraying job file 943 to start the spraying operation by the spraying means 1 as shown in Fig. 3(b). Also, receiving a command from the robot arm position movement control unit 914, the traversing device 5 and the elevating device 7 are operated based on the movement information of the base unit 4 to move the base unit 4 in the horizontal direction and the height direction.

[0075] As a result, the spraying means 1 discharges the refractory coating material C from the gun head 12 and moves in the lateral direction and the height direction along the construction target surface 101a to spray the refractory coating material C over the entire work section E1. At this time, it is desirable to protect the laser light emitting unit 23 of the distance measuring means 2 with the protective cap 24 so that the scattered refractory coating material C does not adhere.

[0076] ≪Distance measurement operation after spraying operation (post-measurement process: Step3-3)≫ After the spraying operation is completed, the arithmetic processing unit 91 receives a command from the robot arm control unit 913 and operates the manipulator 3 based on the measurement job file 942, starting the distance measurement operation by the distance measurement means 2 as shown in Fig. 3(c). Also, upon receiving a command from the robot arm position movement control unit 914, the traversing device 5 and the elevating device 7 are operated based on the movement information of the base unit 4 to move the base unit 4 in the horizontal and height directions.

[0077] Thereby, while the distance measurement means 2 reciprocates along the longitudinal direction of the beam member 101 along the same movement path Tr as in the pre-measurement process (Step 3-1), the distance measurement operation is performed while sequentially opposing the direction of the laser light emitting unit 23 to the measurement lines R1 to R7. The post-spraying distance measured value D2 acquired by the distance measurement means 2 is sequentially stored in the thickness confirmation file 945 provided in the storage unit 94 of the spraying management device 9 after being associated with the position information of the measured position.

[0078] ≪Post-spraying Spraying Thickness Confirmation Operation (Spraying Thickness Confirmation Process: Step 4)≫ After the post-spraying distance measured value D2 is stored in the storage unit 94, the arithmetic processing unit 91 receives a command from the spraying thickness confirmation unit 915 and calculates the measured thickness value D of the refractory coating material C along the measurement lines R1 to R7 or for each measurement point M. As shown in Fig. 3(c), the measured thickness value D is the difference between the pre-spraying distance measured value D1 stored in the thickness confirmation file 945 of the storage unit 94 and the post-spraying distance measured value D2.

[0079] Also, the calculated measured thickness value D is compared with the reference value S of the spraying thickness stored in the thickness confirmation file 945 of the storage unit 94 to verify whether the measured thickness value D satisfies the reference value S. If there is a measurement position that does not satisfy the reference value S, the position information and the insufficient spraying thickness are stored in the thickness confirmation file 945 of the storage unit 94.

[0080] After that, the arithmetic processing unit 91 receives a command from the job file correction unit 912, and based on the information regarding the position where the spraying thickness is insufficient and the insufficient spraying thickness stored in the thickness confirmation file 945, rewrites the spraying job file, and creates a respraying job file 944 for performing the spraying operation again. The respraying job file 944 is stored in the storage unit of the arithmetic processing unit 91.

[0081] ≪Respraying operation≫ When the respraying job file 944 is stored, the arithmetic processing unit 91 receives a command from the robot arm control unit 913, operates the manipulator 3 based on the respraying job file, and starts the respraying operation by the spraying means 1. Also, if necessary, it receives a command from the robot arm position movement control unit 914, operates the traversing device 5 and the lifting device 7 based on the movement information of the base unit 4, and moves the base unit 4 in the horizontal direction and the height direction.

[0082] After the respraying operation is completed, the post-measurement process: Step3-3 is performed again to obtain the actually measured value D2 of the distance after spraying. Also, the spraying thickness confirmation process (Step4) is performed to conduct a verification operation to confirm that the reference value S is satisfied. When it is confirmed that the actually measured value D of the thickness satisfies the reference value S along the measurement lines R1 to R7 or for each measurement point M, the operation by the entire spraying construction system 10 is completed.

[0083] After that, the spraying construction system 10 is retracted to the robot station S, and refractory finishing is performed by pressing with a trowel in the work section E1. As described above, the reference value S is set to the sum of the specified thickness S1 and the allowance S2 considering the reduction in bulk due to pressing with a trowel. Therefore, the spraying thickness on the construction target surface 101a after pressing with a trowel satisfies the specified thickness S1.

[0084] On the other hand, the spraying construction system 10 that temporarily retreats to the robot station S starts moving toward the target position G2 in order to start the spraying construction in the next work section S2. After repeating the above operations for all the work sections set in advance in the pretreatment process (Step 1), the spraying construction is completed.

[0085] ≪≪When performing distance measurement work after pressing with a trowel≫≫ When performing the distance measurement work after spraying after pressing with a trowel, the reference value S of the spraying thickness is set to the same quantity as the specified thickness S1. At this time, it is preferable to perform the trowel pressing without moving the traveling section B of the spraying construction system 10. In this way, the movement path Tr of the distance measuring means 2 can surely reproduce the movement path Tr during the distance measurement work before the spraying work. As a result, the acquisition positions of the pre-spraying distance measured value D1 and the post-spraying distance measured value D2 can be surely made to coincide, so that the thickness confirmation work can be carried out with high accuracy.

[0086] However, when it is necessary to move the spraying construction system 10 together with the traveling section B during the trowel pressing work, for example, the following work may be added. The plan view position, traveling direction, and posture related to the center of gravity of the traveling section B before movement are acquired using the self-position detection sensor 81 and the posture detection sensor 83, and stored in the data file 941 of the storage unit 94. Then, when installing the spraying construction system 10 at the position before movement after trowel pressing, it may be controlled by the installation control unit 911 provided in the arithmetic processing unit 91 so that the plan view position and traveling direction related to the center of gravity of the traveling section B match the above data before movement stored in the storage unit 94.

[0087] According to the spraying construction system and the spraying method of the present invention, the distance measurement work can be carried out with high reproducibility before and after the spraying work, and the pre-spraying distance measured value D1 and the post-spraying distance measured value D2 can be obtained. Therefore, it is possible to efficiently obtain the spraying thickness D without the need for complicated work such as using special jigs or performing complicated data processing.

[0088] Also, during the spraying operation, the robot arm A is operated based on the spraying job file 943, and during the distance measurement operation, it is operated based on the measurement job file 942. Therefore, the spraying means 1 and the distance measurement means 2 can be moved to suitable postures respectively, and while ensuring the efficiency of the spraying operation, the distance measurement operation can be carried out while ensuring high accuracy at the desired measurement position on the construction target surface 101a. As a result, it becomes possible to obtain a highly reliable actually measured thickness value D.

[0089] The spraying construction system 10 of the present invention and the spraying method using the spraying construction system 10 are not limited to the above-described embodiment, and various modifications are possible without departing from the gist of the present invention.

[0090] For example, in the present embodiment, the case where the surface of the beam member 101 of the building 100 is used as the construction target surface 101a and the fireproof coating material C is sprayed is cited as an example, but the construction target surface 101a can be any surface, and the spraying material is not limited to the fireproof coating material C.

[0091] Also, the distance measurement operation by the distance measurement means 2 may be controlled using the spraying management device 9 so as to be automatically started in conjunction with the operation of the manipulator 3 based on the measurement job file 942. Alternatively, after the operator operates the distance measurement means 2 into a measurable state via a remote control or an operator terminal 20 capable of communicating with the spraying management device 9 as shown in FIG. 9, the operation of the manipulator 3 may be started. The same applies to the spraying operation by the spraying means 1.

[0092] Furthermore, the operation of the spraying construction system 10 may be such that the operator directly inputs operation start information using the input unit 92 of the spraying management device 9, or transmits the operation start information using the above-described remote control or operator terminal 20. For example, when the operator has an operator terminal 20 capable of communicating with the spraying management device 9, the spraying construction system 10 may be provided with a communication unit 95 that performs data transmission and reception with the operator terminal 20 via a communication network 30 as shown in FIG. 9.

[0093] As the communication network 30, it may be constructed by any means such as the Internet or a dedicated communication line. Thus, an operator can use a wirelessly communicable operator terminal 20 such as a personal computer, a notebook PC, a tablet terminal, or a smartphone to transmit the operation information of the spraying construction system 10 to the spraying management device 9 and operate the spraying construction system 10. Also, it becomes possible to acquire various information stored in the storage unit 94 of the spraying management device 9 via the operator terminal 20.

[0094] In addition, in the present embodiment, only one robot arm A is mounted on the traveling unit B, but it is not necessarily limited to this, and a configuration in which a plurality of robot arms A are mounted may be adopted. At this time, a plurality of robot arms A may be installed on one traversing device 5, or a plurality of traversing devices 5 may be prepared for each of the plurality of robot arms A.

[0095] In addition, the spraying method of the present invention does not necessarily have to use the spraying construction system 10 as long as it is provided with the distance measuring means 2, and it may be carried out using other moving means.

[0096] Also, the spraying method of the present invention can also be adopted for spraying construction without performing trowel pressing. In this case, it may be carried out in accordance with the procedure when performing distance measurement after the spraying operation before trowel pressing.

Explanation of Reference Numerals

[0097] 10 Spraying construction system 1 Spraying means 11 Spraying main body 12 Gun head 13 Connecting part 2 Distance measuring means 21 Distance measuring instrument 22 Connection jig 23 Laser emitting part 24 Protection cap 3 Manipulator 4 Base part 5 Traversing device 51 Frame 52 Traveling frame 6 Traveling carriage 61 Rectangular top plate 62 Carriage body 63 Traveling means 64 Outrigger device 7 Lifting device 81 Self-position detection sensor 82 Height detection sensor 83 Attitude detection sensor 9 Spraying management device 91 Arithmetic processing unit 911 Mounting control section 912 Job file modification section 913 Robot arm control section 914 Robot arm position movement control section 915 Spraying thickness confirmation section 92 Input section 93 Output section 94 Memory section 95 Communication section 941 Data file 942 Measurement job file 943 Spraying job file 944 Respraying job file 945 Thickness confirmation file 100 Building 101 Beam member 101a Construction target surface A Robot arm B Traveling section C Fireproof coating material (spraying material) D Measured thickness value D1 Measured distance value before spraying D2 Measured distance value after spraying E1E2 Working section G1G2 Target position P Home position R1~R7 Measurement lines Tr Movement path L Laser light S Robot station

Claims

1. A spraying method for spraying a refractory coating material made of a material containing rock wool granular cotton and a cement-based hardening material onto a construction target surface of a building, comprising: Before the spraying operation, a pre-measurement step of measuring the distance from the construction target surface at a plurality of measurement points set in advance on the construction target surface while moving a distance measuring means along the construction target surface; After performing the spraying operation on the construction target surface, a post-measurement step of measuring the distance from the construction target surface while moving the distance measuring means along the path where it was moved in the pre-measurement step; A spraying thickness confirmation step of confirming the spraying thickness based on the pre-spraying distance measured value obtained in the pre-measurement step and the post-spraying distance measured value obtained in the post-measurement step. The method is characterized in that: The post-measurement step is performed after the spraying operation and before performing a refractory finishing operation of pressing the surface of the sprayed refractory coating material; In the spraying thickness confirmation step, it is confirmed whether the difference between the pre-spraying distance measured value and the post-spraying distance measured value satisfies the thickness obtained by adding the specification thickness and the allowance considering the reduction in bulk due to the refractory finishing. This is a spraying method.

2. In the spraying method according to Claim 1, The construction target surface is a beam member, The distance measurement from the construction target surface is performed using a distance measuring means connected to the spraying body of a spraying means comprising a cylindrical spraying body and a gun head provided at its tip for spraying a refractory coating material, The spraying means is provided on a robot arm mounted on a traveling unit, The traveling unit includes a base unit for supporting the robot arm, a lifting device for lifting the robot arm, a traversing device for continuously moving the robot arm in at least the direction along the construction target surface on the traveling unit, and a traveling carriage for supporting the lifting device and the traversing device, The traversing device has a traveling gantry and a frame on which the traveling gantry moves, The base unit is installed on the traveling gantry, moves on the frame, and rotatably supports the robot arm within its upper surface. This is a spraying method.

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