Painting work management system and painting work management method

Abstract

To enable the proper film thickness of a coating material to be formed on a coating object material when a worker manually performs coating.SOLUTION: A coating work management system comprises: a coating gun; a coating material supply device; a measurement device which measures the position and posture of the coating gun; and a coating work management device which calculates a film thickness formation pattern to be formed on the coating object material. The coating work management device holds information on a film thickness pattern associated with a coating condition, selects the film thickness pattern on the basis of the information on the film thickness pattern associated with the coating condition, the coating condition at a time of one coating and the coating gun position and posture at the time of the coating, calculates the movement speed of the coating gun from the positions and postures from time to time of the coating gun, integrates a film thickness value indicating the film thickness pattern for a certain period from the calculated movement speed of the coating gun and the selected film thickness pattern, and calculates the film thickness formation pattern to be formed on the coating object material and coordinate values thereof.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a painting work management system and a painting work management method, and more particularly to a painting work management system and a painting work management method suitable for forming an appropriate paint film thickness on an object to be painted when painting is performed by an operator.

Background Art

[0002] Many structures such as buildings are painted for the purpose of imparting design and protection. In particular, in moving bodies such as railway vehicles and automobiles, it is necessary to smooth the paint film surface in order to impart aesthetics and reduce air resistance.

[0003] The paint film may be a single layer, but in many cases it is made into multiple layers in order to ensure the property of smoothing the paint film surface. For example, when forming a paint film on a metal surface, after roughening the metal surface by blasting or the like, application and drying of a rust preventive primer, application, drying, and polishing of putty to cover the unevenness of the metal surface and ensure smoothness, application, drying, and polishing of a surfacer to cover the fine unevenness of the putty surface, application, drying, and polishing of an intermediate coat, and application, drying, and polishing of a top coat for imparting design to the outermost surface are carried out in this order.

[0004] Painting is generally performed manually by an operator or using an automatic machine such as a robot. When an operator performs painting, a spray, brush, roller, etc. are used, but it is difficult to quantitatively grasp the paint film thickness during painting in real time or immediately after painting, and it strongly depends on the skill of the operator.

[0005] On the other hand, when using a robot, the equipment investment is expensive, and when using a paint containing an organic solvent, it is necessary to have an explosion-proof specification, which further increases the equipment investment amount. In addition, when installing a robot or heating the object to be painted, a process of retracting the robot or a process of moving the object to be painted and heating it is required.

[0006] In robot painting, there is a method of obtaining the paint film thickness distribution by simulation. For example, Patent Document 1 discloses a "paint film thickness simulation method" as a simulation technique. According to the simulation method of Patent Document 1, the film thickness distribution value at the paint gun position is obtained based on a reference pattern, and the film thickness distribution values are integrated to obtain the film thickness distribution value of the object to be painted.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0008] The method of Patent Document 1 relates to robot painting and requires capital investment. In addition, generally, painting of complex structures often relies on manual labor, and manual labor cannot be eliminated in painting operations.

[0009] Generally, when painting is performed manually by an operator or using a robot, attention must be paid to the paint film thickness when painting. If it is thinner than the predetermined film thickness, problems such as weak protection by painting or inability to obtain the required aesthetics may occur. If it is thicker than the predetermined film thickness, problems such as so-called swelling or cracking may occur due to the solvent remaining in the paint film and vaporizing, or the cost may increase due to the use of a large amount of paint. In addition, when these occur in combination, the aesthetics may be impaired due to unevenness or the like. To prevent these, it is necessary to ensure an appropriate film thickness.

[0010] An object of the present invention is to provide a painting operation management system and a painting operation management method that enable an appropriate paint film thickness to be formed on an object to be painted when the painting is performed manually by an operator.

Means for Solving the Problems

[0011] The configuration of the painting operation management system of the present invention is preferably a painting operation management system for managing a painting operation of painting an object to be painted by spraying paint with a paint gun, including a paint supply device for supplying paint to the paint gun, a measuring device for measuring the position and posture of the paint gun at any time, inputting information about the paint from the paint supply device and information about the paint gun from the measuring device for measuring the position and posture of the paint gun at any time, and calculating a film thickness formation pattern formed on the object to be painted. The painting operation management device holds information on the film thickness pattern associated with the painting conditions. Based on the information on the film thickness pattern associated with the painting conditions, the painting conditions at a certain painting time, and the position and posture of the paint gun at the painting time, the painting operation management device selects a film thickness pattern, calculates the moving speed of the paint gun from the position and posture of the paint gun at any time, integrates the film thickness values indicated by the film thickness pattern from the calculated moving speed of the paint gun and the selected film thickness pattern for a certain period, and calculates the film thickness formation pattern formed on the object to be painted and the coordinate values of the film thickness formation pattern.

Advantages of the Invention

[0012] According to the present invention, it is possible to provide a painting operation management system and a painting operation management method that enable an appropriate paint film thickness to be formed on an object to be painted when the painting is manually performed by an operator.

Brief Description of the Drawings

[0013]

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Embodiments for Carrying Out the Invention

[0014] Hereinafter, an embodiment of the present invention will be described with reference to FIGS. 1 to 19. First, the configuration of the painting work management system will be described with reference to FIGS. 1 to 3.

[0015] First, the overall configuration of the painting work management system will be described with reference to FIG. 1. The painting work management system is a system that supports mainly manual painting work on the object to be painted 10. The operator 1 discharges and sprays the paint 4 from the paint gun 40, and at the same time, moves the paint gun parallel to the painting surface of the object to be painted 10, thereby applying the paint 4 to the painting surface of the object to be painted 10. In the following embodiments, the case where the object to be painted 10 is a railway vehicle will be taken as an example for explanation.

[0016] As shown in FIG. 1, the painting work management system includes an AR-HMD (Augmented Reality Head Mounted Display) 20, cameras 30 (denoted as 30a and 30b in FIG. 1), a paint gun 40, a painting work management device 100, and a paint supply device 300.

[0017] The painting gun 40 is a painting device that utilizes compressed air from a compressor (not shown) to spray a liquid such as paint 4 in a mist form onto an object. A typical form of the painting gun 40 has a shape like a pistol, and the paint is sprayed by pulling a trigger.

[0018] The painting gun 40 is connected by a hose 50 to a paint supply device 300. The discharge amount (paint flow rate) of the paint discharged from the painting gun 40 is recorded by a paint supply device that automatically mixes a plurality of paint components, and is reported to the painting operation management device 100 via a wired or wireless network or a connection line. Further, in this embodiment, it is assumed that the painting gun 40 is an air gun, which is connected by a compressor (not shown) and an air hose, and the air flow rate and the like of the air discharged simultaneously with the paint are also recorded and reported to the painting operation management device 100.

[0019] Also, a marker 41 that can grasp the position and orientation of the painting gun 40 with respect to the object to be painted 10 is attached to the painting gun 40 of this embodiment. The marker 41 indicates the gun position, for example, by transmitting visible light, infrared rays, or radio waves, and a plurality of markers (for example, three locations) are attached to indicate the orientation.

[0020] Then, the position and orientation of the painting gun 40 are calculated based on the position information received from the marker 41 of the painting gun 40. As a receiving method, for example, a form in which radio waves transmitted from the marker 41 are captured by a sensor or a plurality of cameras 30 can be considered.

[0021] Note that the painting gun 40 of this embodiment may be in any form such as an air gun, an airless gun, or an electrostatic gun.

[0022] The camera 30 is a device that photographs the painting operation of the operator 1 and transfers the image to the painting operation management device 100 via a wired or wireless network. Also, as described above, the position, orientation, and movement speed of the painting gun 40 may be transmitted to the painting operation management device 100 by the camera 30.

[0023] The AR-HMD20 is a display that is worn on the head of the operator 1 to display the necessary information for the painting operation. For example, in accordance with instructions from the painting operation management device 100, the operator 1 is informed of the current film thickness of the object to be painted 10, and information is displayed to the operator so that there is no excess or deficiency in the film thickness during the painting operation. The details of the user interface provided by the AR-HMD20 will be described later.

[0024] The paint supply device 300 is a device that mixes paint stock solution and solvents, etc., and supplies paint to the painting gun 40 through the hose 50. The paint discharge amount is sometimes recorded and reported to the painting operation management device 100 via a network or connection line.

[0025] The painting operation management device 100 is a device that manages the entire painting operation of the operator 1 and displays the necessary information on the AR-HMD20. In particular, the painting operation management device 100 calculates the film thickness of the paint on the object to be painted 10 from the paint flow rate, air flow rate discharged from the painting gun 40, and the position, orientation, and moving speed of the painting gun 40 with respect to the object to be painted 10. The method of calculating the film thickness of the paint on the object to be painted 10 will be described in detail later.

[0026] Next, the functional configuration of the painting operation management device will be described with reference to FIG. 2. As shown in FIG. 2, the painting operation management device 100 includes functional units such as a painting information input unit 101, a painting amount / air amount IF (InterFace) unit 102, an imaging information IF unit 103, a film thickness pattern search unit 104, a painting gun speed calculation unit 105, a film thickness calculation unit 106, an HMD data editing unit 107, an HMD data output unit 108, and a storage unit 110.

[0027] The painting information input unit 101 is a functional unit for an operator 1 of the painting operation or a work manager to input information related to the painting operation. The paint application amount / air amount IF (InterFace) unit 102 is a functional unit for receiving the paint discharge amount and air flow rate from the paint supply device 300. The imaging information / sensor information IF unit 103 is a functional unit for receiving imaging information from the camera 30 or information from various sensors. The film thickness pattern search unit 104 is a functional unit for searching for a film thickness pattern (details will be described later) based on conditions related to painting. The painting gun speed calculation unit 105 is a functional unit for calculating the moving speed of the painting gun 40 based on information input from measuring devices such as the camera 30 and sensors. The film thickness calculation unit 106 is a functional unit for calculating the film thickness formed on the object to be painted based on the film thickness pattern and the moving speed of the painting gun 40. The HMD data editing unit 107 is a functional unit for editing data for the information displayed on the AR-HMD 20. The HMD data output unit 108 is a functional unit for outputting data to the AR-HMD 20. The storage unit 110 is a functional unit for storing data used in the painting operation management device 100.

[0028] The storage unit 110 holds various tables such as a painting operation information table 500, a film thickness pattern table 501, a film thickness pattern 502, a painting condition table 503, a painting gun moving speed table 504, a film thickness result table 505, and a film thickness formation pattern 506.

[0029] Note that the details of each table will be described later.

[0030] Next, the hardware and software configuration of the painting operation management device 100 will be described with reference to FIG. 3. As the hardware configuration of the painting operation management device 100, for example, it is realized by a general information processing device such as the personal computer shown in FIG. 3. However, as long as the functions shown in FIG. 2 can be executed, a system that executes the functions by a cloud system may also be used.

[0031] The painting operation management device 100 has a form in which a processor 402, a main memory device 404, a network I / F (InterFace) 406, a display I / F 408, an input / output I / F 410, and an auxiliary storage I / F 412 are connected by a bus.

[0032] The processor 402 controls each part of the painting operation management device 100, loads and executes necessary programs in the main memory device 404. As an example of the processor, a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit) can be considered, but other semiconductor devices may also be used as long as they are the main body for executing predetermined processing.

[0033] The main memory device 404 is usually composed of a volatile memory such as a RAM, and stores programs executed by the CPU 402 and data to be referenced.

[0034] The network I / F 406 is an interface for connecting to the network 5.

[0035] The display I / F 408 is an interface for connecting a display device 420 such as an LCD (Liquid Crystal Display).

[0036] The input / output I / F 410 is an interface for connecting input / output devices. In the example of FIG. 3, a keyboard 430 and a mouse 432 as a pointing device are connected.

[0037] The auxiliary storage I / F 412 is an interface for connecting an auxiliary storage device such as an HDD (Hard Disk Drive) 450 or an SSD (Solid State Drive).

[0038] The HDD 450 has a large storage capacity and stores a program for executing the present embodiment. In the painting work management device 100, a painting information input program 461, a paint amount / air amount IF program 462, an imaging information IF program 463, a film thickness pattern search program 464, a painting gun speed calculation program 465, a film thickness calculation program 466, an HMD data editing program 467, and an HMD data output program 468 are installed.

[0039] The painting information input program 461, the paint amount / air amount IF program 462, the imaging information IF program 463, the film thickness pattern search program 464, the painting gun speed calculation program 465, the film thickness calculation program 466, the HMD data editing program 467, and the HMD data output program 468 are programs that realize the functions of the painting information input unit 101, the paint amount / air amount IF unit 102, the imaging information IF unit 103, the film thickness pattern search unit 104, the painting gun speed calculation unit 105, the film thickness calculation unit 106, the HMD data editing unit 107, and the HMD data output unit 108, respectively.

[0040] Each program may be provided by a storage medium such as a CD-ROM or a DVD-ROM, or may be distributed by a program distribution server via the Internet or the like.

[0041] Next, the data structure used in the painting work management system will be described with reference to FIGS. 4 to 10.

[0042] The painting work information table 500 is a table that holds information for managing painting work. As shown in FIG. 4, it has fields such as a work ID 500a, an operator 500b, a painting vehicle type 500c, a painting gun product name 500d, a nozzle diameter 500e, a painting location 500f, a paint product name 500g, a dilution rate h, a work start date and time 500i, a work end date and time 500j, a film thickness lower limit 500k, a film thickness upper limit 500l, and a post-work instruction 500m.

[0043] The operation ID 500a stores an ID that uniquely identifies the painting operation. The operator 500b stores a string representing the operator or the operator's ID. The painted vehicle type 500c stores a string representing the vehicle related to the painting operation or the vehicle's ID. The painting gun product name 500d stores the product name of the painting gun 40 input from the input device of the painting operation management device 100. The nozzle diameter 500e stores the value of the diameter of the discharge port of the painting gun 40 with the painting gun product name 500d in mm units. The painting location 500f stores information on the part of the vehicle related to the painting operation. The paint product name 500g stores information on the product name of the paint. The operation start date and time 500i stores information on the date and time when the operation started in the format of yyyymmddhhmm. The operation end date and time 500j stores information on the date and time when the operation ended in the format of yyyymmddhhmm. The film thickness lower limit 500k stores the value of the lower limit of the painting specified in the painting operation (the limit where the film thickness should not be thinner than this) in μm units. The film thickness upper limit 500l stores the value of the upper limit of the painting specified in the painting operation (the limit where the film thickness should not be thicker than this) in μm units. The post-operation instruction 500m stores a string or ID indicating the content of the operation when necessary after the painting operation.

[0044] The film thickness pattern table 501 is a table that holds the correspondence between the painting conditions and the formed film thickness pattern. As shown in FIG. 5, it has fields for each of the paint product name 501a, dilution ratio 501b, paint flow rate 501c, discharge air flow rate 501d, control air flow rate 501e, painting gun product name 501f, nozzle diameter 501g, gun distance 501h, horizontal angle 501i, vertical angle 501j, and film thickness pattern 501k.

[0045] For paint name 501a, information on the paint name is stored. For dilution ratio 501b, the dilution ratio of the paint is stored. The dilution ratio is generally defined as (volume of undiluted paint + volume of thinner) / (volume of thinner). For paint flow rate 501c, the value of the paint flow rate per unit time recorded by the paint supply device 300 is stored in mL / s units. For ejection air flow rate 501d, the value of the air flow rate per unit time ejected from the painting gun 40 is stored in mL / s units. For control air flow rate 501e, the value of the air flow rate per unit time controlled by the paint supply device 300 is stored in mL / s units. For painting gun name 501f, the name of the painting gun 40 is stored. For nozzle diameter 501g, the value of the diameter of the discharge port of the painting gun 40 is stored in mm units. For gun distance 501h, the vertical distance between the painting gun 40 and the object to be painted 10 is stored in m units. For horizontal angle 501i, the value of the horizontal angle of the tip of the painting gun 40 is stored in degrees. For vertical angle 501j, the value of the vertical angle of the tip of the painting gun 40 is stored in degrees. For film thickness pattern 501k, a character string or ID that uniquely indicates the film thickness pattern described below is stored.

[0046] In the example of FIG. 5, the values of paint name 501a, dilution ratio 501b, paint flow rate 501c, ejection air flow rate 501d, control air flow rate 501e, painting gun name 501f, nozzle diameter 501g, gun distance 501h, horizontal angle 501i, and vertical angle 501j are each converted into a character string, and the character string concatenated by "-" is used as the value of the film thickness pattern 501k.

[0047] As shown in FIGS. 6A to 6E, the film thickness pattern 502 is a data structure that shows the film thickness of the paint during painting formed on the surface of the object to be painted 10 per unit time in μm units for each unit lattice. In FIGS. 6A to 6E, 1 s is taken as the unit time, and the unit lattice is a lattice of 10 mm square. And the center of the film thickness pattern 502 is the intersection of the extension line in the nozzle direction of the painting gun 40 and the surface of the object to be painted 10.

[0048] Regarding the painting conditions, the film thickness pattern formed can be measured by means such as a film thickness gauge through painting experiments on the actual object to be painted under those painting conditions, or can be obtained through numerical calculations or computer simulations.

[0049] The painting condition table 503 is a table that holds the conditions in the actual painting operation. As shown in FIG. 7, it has fields for work ID 503a, date and time 503b, paint name 503c, dilution ratio 503d, nozzle diameter 503e, painting gun name 503g, paint flow rate 503g, ejection air flow rate 503h, control air flow rate 503i, gun position (x) 503j, gun position (y) 503k, gun distance 503g, horizontal angle 503m, and vertical angle 503i.

[0050] For the operation ID 503a, an ID that uniquely identifies the painting operation is stored. For the date and time 503b, the date and time when the operation is being performed in the yyyymmddhhmmss format is stored. For the paint name 503c, information on the name of the paint input by the operator or administrator before the operation is stored. For the dilution ratio 503d, the dilution ratio of the paint stored in the painting operation information table 500 is stored. For the nozzle diameter 503e, the value of the diameter of the discharge port of the painting gun 40 stored in the painting operation information table 500 is stored in mm units. For the painting gun name 503g, the name of the painting gun 40 input by the operator or administrator before the operation is stored. For the paint flow rate 503g, the value of the paint flow rate per unit time measured by a built-in or external paint flow meter in the paint supply device 300 is stored in mL / s units. For the discharge air flow rate 503h, the value of the air flow rate per unit time discharged from the painting gun 40 measured by an air flow meter is stored in mL / s units. For the control air flow rate 503i, the value of the air flow rate per unit time supplied by a compressor (not shown) is stored in mL / s units. For the gun position (x) 503j, the position of the x coordinate of the reference point of the painting gun 40 (for example, the tip of the nozzle of the painting gun 40) measured by the camera 30 or sensor is stored in m units. For the gun position (y) 503k, the position of the y coordinate of the reference point of the painting gun 40 measured by the camera 30 or sensor is stored in m units. For the gun distance 503g, the position from the reference point of the painting gun 40 to the surface of the object to be painted measured by the camera 30 or sensor (in this embodiment, made equal to the z coordinate (details will be described later)) is stored. For the horizontal angle 503m, the value of the horizontal angle of the tip of the painting gun 40 measured by the camera 30 or sensor is stored in degrees. For the vertical angle 503i, the value of the vertical angle of the tip of the painting gun 40 measured by the camera 30 or sensor is stored in degrees.

[0051] The painting gun movement speed table 504 is a table that holds information regarding the movement speed of the painting gun 40 calculated from the time information and position information of the painting gun 40. As shown in FIG. 8, it has fields for work ID 504a, date and time 504b, movement speed (x direction) 504c, movement speed (y direction) 504d, and movement speed (z direction) 504e.

[0052] The work ID 504a stores an ID that uniquely identifies the painting operation. The date and time 504b stores the date and time when the movement speed of the painting gun 40 was calculated in the yyyymmddhhmmss format. The movement speed (x direction) 504c, movement speed (y direction) 504d, and movement speed (z direction) 504e store the values of the movement speed of the painting gun 40 in the x direction, y direction, and z direction, respectively, calculated from the time information and position information of the painting gun 40, in the form of m / s.

[0053] The film thickness result table 505 is a table that holds information regarding the film thickness of the paint formed on the surface of the object to be painted 10 calculated from the painting conditions, the movement speed of the painting gun 40, and the film thickness pattern. As shown in FIG. 9, it has fields for work ID 505a, date and time 505b, film thickness formation pattern 505c, and pattern coordinates 505d.

[0054] The work ID 505a stores an ID that uniquely identifies the painting operation. The date and time 505b stores the date and time when it was calculated that the film thickness indicated by the film thickness formation pattern 505c was formed in the yyyymmddhhmmss format. The film thickness formation pattern 505c stores a character string or ID indicating the film thickness formation pattern 505c. In this embodiment, it is a character string obtained by adding a prefix (RS) to the character string indicating the film thickness pattern used to generate the film thickness formation pattern. The pattern coordinates 505d store, for example, a pair of values of the x coordinate and y coordinate indicating the center part of the film thickness formation pattern 505c.

[0055] The film thickness formation pattern 506 is a data structure that shows the film thickness of the paint during painting formed on the surface of the object to be painted 10 in μm units for each unit cell, as shown in FIG. 10. Each unit cell in FIG. 10 corresponds to the unit cell of the film thickness pattern shown in FIGS. 6A to 6E.

[0056] Next, the processing of the painting operation management system will be described with reference to FIGS. 11 to 14C.

[0057] First, the structure of a railway vehicle will be described as an example of the object to be painted with reference to FIG. 11. The outer wall 605 of the railway vehicle 601 shown in FIG. 11 is formed by a side surface portion and an upper surface portion that is the ceiling portion, and they are formed by processed materials obtained by processing metal plates. On the side surface portion of the railway vehicle, a door portion 603 and a window portion 604, which are opening and closing doors, are provided. Further, a pantograph 606 is provided on the upper surface portion of the railway vehicle. The railway vehicle is supported by a bogie portion 602, and the railway vehicle 601 is moved by the rotation of wheels 607 on the rail.

[0058] In the outer wall of the railway vehicle, in this embodiment, a paint film is formed by an operator spraying paint with a paint gun 40 within a specified range of a predetermined film thickness. By covering the surface of the metal material with the paint film of the embodiment, the surface of the metal material is physically protected, and direct contact with foreign substances and rainwater and the like on the surface of the metal material is prevented. Therefore, the occurrence of metal corrosion on the surface of the metal material can be effectively prevented. Further, by using a colored topcoat, the designability can be imparted to the railway vehicle.

[0059] Next, the premise for the painting operation management device to calculate the film thickness of the paint formed on the object to be painted will be described with reference to FIGS. 12 to 14C.

[0060] In this embodiment, as shown in FIG. 12, as a coordinate system, the x-axis and y-axis of the orthogonal coordinate system are arranged on the surface of the object to be painted (railway vehicle) 10, and the z-axis is arranged in the direction perpendicular to the surface. Therefore, the distance between the surface of the object to be painted 10 and the tip nozzle of the paint gun 40 is equal to the value of the z-axis.

[0061] Also, as shown in FIG. 13, a marker 41 is set on the painting gun 40, and the position and posture of the painting gun 40 at each time are measured by the camera 30 or the sensor. Further, the paint flow rate per unit time sent to the painting gun 40 is measured by a paint flow meter, and the value of the air flow rate per unit time (discharge air flow rate) discharged from the painting gun 40 measured by an air flow meter and the value of the air flow rate per unit time (controlled air flow rate) supplied by the compressor are measured.

[0062] The operator 1 moves the painting gun 40 in the x-axis or y-axis direction while maintaining a certain distance from the surface of the object to be painted 10, and sprays the paint with the painting gun 40. At this time, the operator 1 can view the information for supporting the painting operation by the AR-HDM20 together with the working situation.

[0063] The relationships regarding the distance between the painting gun 40 and the object to be painted 10 and the posture of the painting gun 40 are as shown in FIGS. 14A to 14C. As shown in FIG. 14A, when the distance between the painting gun 40 and the object to be painted 10 is far, the film thickness formed on the surface of the object to be painted 10 becomes thin. As shown in FIG. 14B, when the distance between the painting gun 40 and the object to be painted 10 is far, the film thickness formed on the surface of the object to be painted 10 becomes thin. Further, as shown in FIG. 14C, when the painting gun 40 is inclined with respect to the surface of the object to be painted 10, thin and thick portions are generated, and the film thickness formed on the surface of the object to be painted 10 becomes non-uniform.

[0064] The painting operation management device 100 of the present embodiment holds a film thickness pattern indicating the film thickness formed per unit time when painting under the position, posture of the painting gun 40 and other painting conditions in this way.

[0065] Next, the processing of the painting operation management device will be described with reference to FIGS. 15A to 18C.

[0066] First, the painter 1 or the administrator of the painting operation inputs the painting vehicle type, information about the worker, and the name of the painting gun via an input screen (not shown) output to the display device of the painting operation management device 100 or via the command line (S100).

[0067] Next, based on the input information, the painting operation management device 100 refers to the painting operation specification data (not shown) and the painting gun specification data (not shown), and sets the information related to painting and the information related to the painting gun in the painting information table 500 (S101).

[0068] When information related to painting and information related to the painting gun cannot be obtained by referring to the painting operation specification data and the painting gun specification data (for example, when the painting vehicle type is known but the name of the paint cannot be uniquely determined), the painter 1 or the administrator of the painting operation inputs such information to the painting operation management device 100.

[0069] Next, when the painter 1 starts the painting operation, the painting operation management device 100 sets the operation start date and time in the operation start date and time 500i of the painting information table 500 (S102).

[0070] The following processes of S103, S104, S105 to S113 are parallel processes.

[0071] The painting operation management device 100 reads the coordinate data and posture of the painting gun 40 from the camera 3 or the sensor at a certain time (S103).

[0072] Also, the painting operation management device 100 reads the paint flow rate from the paint meter and the air flow rate (sprayed air flow rate, control air flow rate) from the air flow meter (S104).

[0073] Also, in parallel with the processes of S103 and S104, based on the values read in S104, S104, the clock information of the painting operation management device 100, and the values set in the painting information table 500, values are set in the painting condition table 503 (S105).

[0074] Next, the painting work management device 100 selects an optimal film thickness pattern from the film thickness patterns stored in the film thickness pattern table 501 based on the values set in the painting condition table 503 (S106).

[0075] For example, the method of selecting the film thickness pattern is to select the film thickness pattern of the record in the film thickness pattern table with the smallest distance from the values set in the painting work information table 500 shown in (Equation 1) of FIG. 16.

[0076] Here, e i (Field value of the painting condition table) is the evaluation value of the field value of the painting condition table 503, e i (Field value of the film thickness pattern table) is the evaluation value of the field value of 501 in the film thickness pattern table, k i (0 ≦ k i ≦ 1) is a weighting coefficient for evaluation.

[0077] Also, the fields of the film thickness pattern table 501 and the fields of the painting condition table 503 for each item are corresponding ones (paint name 501a: paint name 503c, dilution rate 501b: dilution rate 503d, paint flow rate 501c: paint flow rate 503g, ejection air flow rate 501d: ejection air flow rate 503h, control air flow rate 501e: control air flow rate 503i, painting gun name 501f: painting gun name 503e, nozzle diameter 501g: nozzle diameter 503f, gun distance 501h: gun distance 503l, horizontal angle 501i: horizontal angle 503m, vertical angle 501j: vertical angle 503n).

[0078] When the field value of the painting condition table 503 and the field value of the film thickness pattern table 501 are equal, the square of the term for which the sum is taken becomes 0, and the more the values are separated, the larger the values become and the greater the distance. Therefore, it is desirable that the evaluation values of the paint name (paint name 501a: paint name 503c) and the painting gun name (painting gun name 501j: painting gun name 503f) give close evaluation values to paints and painting guns with similar specifications.

[0079] Also, the weighting coefficient k for each evaluation i can be determined to be a desirable value by a supervised machine learning method.

[0080] Next, the painting work management device 100 calculates the moving speed of the paint gun 40 at (x, y, z) at the time of the date and time 503b of the painting condition table 503 from the coordinate data and posture of the camera 3 or the sensor at each time, and sets the value in the paint gun moving speed table 504 (S107).

[0081] Next, the painting work management device 100 calculates the coordinate position and film thickness where the film thickness is formed based on the value in the paint gun moving speed table 504 and the film thickness pattern selected in S106, and sets the film thickness formation pattern and its coordinate position in the film thickness result table 505 (S108).

[0082] The coordinate position where the film thickness is formed is the intersection of the nozzle direction of the paint gun 40 and the surface of the object to be painted 10, and this also becomes the center position of the film thickness formation pattern.

[0083] The value of the film thickness formation pattern in the unit lattice (i, j) of the film thickness formation pattern is calculated by (Equation 2) in FIG. 17. k in Σ of (Equation 2) is an integer of 1 or more that satisfies (Equation 3) in FIG. 17. Here, T is the time interval for calculating the film thickness formation pattern, and Δt is the unit of time increment. Also, r in (Equation 2) x , r y are the painting efficiency coefficients in the x - direction and y - direction respectively, and are shown by (Equation 4) in FIG. 17. This is equal to the time during which the paint is sprayed onto one unit lattice within the unit of time increment Δt.

[0084] Hereinafter, the process of calculating the film thickness formation pattern will be specifically described with reference to FIGS. 18A to 18C.

[0085] In this example, only the film thickness formation pattern formed by the movement in the x direction is shown. The time interval T for calculating the film thickness formation pattern is T = 60 [s] = 1 [minute], and Δt = 1 / 100 [s]. When the moving speed in the x direction is 100 [mm / s], if one side of the unit lattice is 10 mm, then r x = 10 [mm] / 100 [mm / s] = 1 / 10 [1 / s], which is the time interval at which the paint is sprayed by the painting gun 40 in terms of the time increment unit Δt.

[0086] Therefore, under certain conditions of the film thickness pattern, the film thickness values formed as a result of being formed per unit time are shown for each unit lattice. So, as shown in (Equation 2) and FIG. 18C, the film thickness formation pattern is obtained by multiplying the painting efficiency coefficient r x in the x direction and the painting efficiency coefficient r y in the y direction for each corresponding unit lattice and then adding them together. FIGS. 18A to 18C show that from the film thickness pattern A-1.0-7.5-5-2.5-G1-1.3-0.2-0-0 every 1 / 100 [s] at the time: 10:10:01:00 to 10:10:02:00, the film thickness formation pattern of RS-A-1.0-7.5-5-2.5-G1-1.3-0.2-0-0 is calculated at the time: 10:10:02:00.

[0087] Next, the painting operation management device 100 refers to the painting operation information table 500, the painting condition table 503, and the film thickness result table 505, and edits the HMD data for output to the AR-HMD 20 (S109).

[0088] Next, the painting operation management device 100 outputs the HMD data edited in S109 to the AR-HMD 20 (S110).

[0089] Next, the painting work management device 100 determines whether or not the painting work has been completed (S111). As the determination criterion for the completion of the painting work, the working time of the painting work may be determined in advance and compared therewith, or an operator or a manager may determine the completion of the painting work and input a command to the painting work management device 100.

[0090] When the painting work has not been completed (S111: NO), the painting work management device 100 determines whether or not the interval T has elapsed since the previous process (S113). When the interval T has elapsed (S113: YES), it returns to S105.

[0091] When the painting work has been completed (S111: YES), the painting work management device 100 sets the work completion date and time in the work completion date and time 500j of the painting work information table 500 (S120).

[0092] Next, the painting work management device 100 stores information regarding the instructions after the completion of the painting work in the post-work instruction 500m of the painting work information table 500, and ends the process.

[0093] For example, the following examples can be considered. 1) In the film thickness formation pattern shown in the film thickness result table 505, when the number of unit cells with a film thickness less than the lower limit value of the film thickness specification is more than a predetermined threshold, repainting of a predetermined location is instructed. 2) In the film thickness formation pattern shown in the film thickness result table 505, when the number of unit cells with a film thickness exceeding the upper limit value of the film thickness specification is more than a predetermined threshold, repairs such as polishing after paint drying are instructed. 3) When the work is completed due to the arrival of the break time of the operator, the restart time of the painting work is instructed.

[0094] Next, the display image of the AR-HDM displayed to the painting operator will be described with reference to FIG. 19. As the HDM display image 700 of the AR-HDM20, as shown in FIG. 19, a time view 710, a work information view 720, a remote view 730, an enlarged view 740, a painting condition view 750, and a STATUS view 760 are displayed.

[0095] The time view 710 displays the current time and the time elapsed since the start of painting to the operator. The work information view 720 displays the necessary information for the operator from the painting work information table 500. The remote view 730 displays the display image when the object to be painted 10 is visually recognized. The enlarged view 740 refers to the film thickness formation pattern shown in the film thickness result table 505 and enlarges and displays the painting status on the object to be painted 10. For example, as shown in FIG. 19, for each unit cell, it is color-coded and displayed whether the film thickness is appropriate, exceeds the specified specification, or does not reach the specified specification. For example, the unit cells within the film thickness specification are displayed in white, the unit cells that have not reached the lower limit of the film thickness are displayed in blue, and the unit cells that have exceeded the upper limit of the film thickness are displayed in red. The area of the object to be painted 10 displayed in the enlarged view 740 may display the vicinity of the area currently being painted, or the operator may be able to specify the area of the object to be painted 10 that they want to view.

[0096] When the painting operation management device 100 detects that the number of unit cells within the film thickness specification exceeds a predetermined threshold during painting by the painter 1 of the painting, it can issue an instruction for overcoating. Also, for the areas that exceed the upper limit of the film thickness, an instruction for wiping during painting can be issued.

[0097] The painting condition view 750 displays the necessary information from the painting condition table 503. The STATUS view 760 displays the current status that the operator wants to know, for example, a warning display when the film thickness of the painting exceeds the upper limit value of the specification as shown in FIG. 19. Alternatively, when an area where the film thickness of the painting is less than the lower limit value of the specification occurs over a certain area, a warning is issued to that effect.

[0098] As the HDM display image 700 of the AR-HDM20, only the remote view 730 may be always displayed, and the necessary view area may be displayed according to the command input of the operator 1.

[0099] As described above, according to the present embodiment, the painting work management device selects a film thickness pattern to be applied by the painting work, calculates the film thickness formation pattern in the painting actually formed on the object to be painted in consideration of the moving speed of the painting gun, and displays the information in real time on the AR-HDM of the operator.

[0100] Thereby, in the painting by the operator's hands, the painting quality is improved by making the painting film thickness uniform, the protectiveness and the aesthetic appearance are ensured by securing the minimum value of the predetermined film thickness, and the cost of painting can be minimized by minimizing the paint usage amount.

Example

[0101] 〔Creation of film thickness pattern〕 First, an aluminum plate was prepared as the object to be painted 10. Specifically, among Al-Mg-Si alloys (6000 series aluminum alloys), a 6N01 alloy with a smooth surface was used. The size is 1 m in length × 1.2 m in width and 2 mm in thickness.

[0102] The aluminum plate of the object to be painted 10 was set vertically, and primer painting was performed. For the primer painting, using an automatic mixer, the Uni-Epox 30 primer NC rust paint liquid (manufactured by Nippon Paint) and the Uni-Epox 30 primer curing agent (manufactured by Nippon Paint) were set to be mixed at a weight ratio of 6:1. The paint flow rate was changed between 5 and 30 mL / second corresponding to the value defined in the paint flow rate 501c of the film thickness pattern table 501 shown in FIG. 5 of the embodiment. Also, the discharge air flow rate was changed between 7.5 and 32.5 mL / second. Further, the painting gun 40 with a nozzle diameter of 1.3 mm was changed from 0.2 to 0.5 m from the aluminum plate of the object to be painted, with a horizontal angle of 0 to 30° and a vertical angle of 0 to 30°.

[0103] The film thickness of the coating film applied under the above conditions was measured using an eddy current thickness gauge over the entire area where the coating film exists at 10 mm intervals vertically, horizontally, and with the center of the applied film as the origin.

[0104] This was held in the film thickness pattern table 501 in correspondence with the conditions as a film thickness pattern as shown in FIGS. 6A to 6E.

[0105] 〔Coating on the object to be coated〕 First, an aluminum plate similar to the object to be coated 10 was prepared. The specific specifications were the same as those in the case of creating the film thickness pattern, which was 6N01 alloy among Al-Mg-Si alloys (6000 series aluminum alloys), with dimensions of 1 m in length × 1.2 m in width and 2 mm in thickness, and a smooth surface was used.

[0106] In order to ensure the adhesion between the object to be coated and the coating film, a blasting treatment was performed. The blasting treatment was carried out by spraying steel crushed particles with a particle diameter of 0.5 mm as abrasive at a projection speed of 35 m / s onto the target aluminum plate. After the spraying was completed, air blowing was performed, and it was visually confirmed that there was no residue of the abrasive.

[0107] The coating was performed in the same manner as when creating the film thickness pattern. For the primer coating, using an automatic mixer, the Uni-Epox 30 primer NC rust paint liquid (manufactured by Nippon Paint) and the Uni-Epox 30 primer curing agent (manufactured by Nippon Paint) were set to be mixed at a weight ratio of 6:1. As shown in the example of the coating condition table 503 in FIG. 7, the paint flow rate was set to 5 mL / second, and the discharge air flow rate was set to 7.5 mL / second. Also, an air spraying gun with a nozzle diameter of 1.3 mm was kept at a distance of 0.2 to 0.3 m from the aluminum plate of the object to be coated, and the variation range was set with the horizontal angle and the vertical angle between 0° ± 30°.

[0108] The coordinate position and orientation of the painting gun 40 were calculated from the camera images of the three LED light emitters attached as markers 41 to the painting gun 40. Also, the moving speed was calculated from the time and the measured coordinate position. As shown in FIGS. 18A to 18C, the film thickness pattern per unit time produced under the same conditions as the painting conditions was selected, the film thickness was reduced to 1 / 10, and the coordinate positions were adjusted according to the moving direction and moving speed and integrated to calculate the film thickness formation pattern.

[0109] The film thickness specification value for painting was set to 40 to 50 μm. Also, for the display on the AR-HMD 20, white-out display was set if it was within the film thickness specification range, blue if the film thickness was less than 40 μm, and red if the film thickness was thicker than 50 μm. As shown in FIG. 19, the numerical value of the film thickness and each color were displayed for each unit lattice. Painting was repeated a plurality of times, and a plurality of film thickness patterns were also added according to the number of painting times, and painting was completed when the film thickness showed 35 to 55 μm.

[0110] The film thickness after painting was measured with an eddy current type film thickness gauge. It was confirmed that the film thickness measured with the film thickness gauge at the location displayed in blue on the AR-HMD 20 was 35 to 39 μm, the film thickness measured with the film thickness gauge at the location displayed in white-out was 40 to 50 μm, and the film thickness measured with the film thickness gauge at the location displayed in red was thicker than 50 μm.

Explanation of Signs

[0111] 1... Operator, 20... AR-HMD (Augmented Reality Head Mounted Display), 30... Camera, 40... Painting gun, 100... Painting operation management device, 300... Paint supply device 101... Painting information input section, 102... Painting amount / air amount IF (InterFace) section, 103... Imaging information IF section, 104... Film thickness pattern search section, 105... Painting gun speed calculation section, 106... Film thickness calculation section, 107... HMD data editing section, 108... HMD data output section, 110... Storage section 500... Painting operation information table, 501... Film thickness pattern table, 502... Film thickness pattern, 503... Painting condition table, 504... Painting gun moving speed table, 505... Film thickness result table, 506... Film thickness formation pattern

Claims

A painting operation management method for a painting operation management system that manages a painting operation of painting an object to be painted by spraying paint with a painting gun, comprising: The painting operation management system includes: A paint supply device that supplies paint to the painting gun; A measuring device that measures the position and posture of the painting gun at various times; A painting operation management device that inputs information about the paint from the paint supply device and information about the painting gun from the measuring device that measures the position and posture of the painting gun at various times, and calculates a film thickness formation pattern to be formed on the object to be painted; It is worn by an operator of the painting operation and includes a head-mounted display on which the object to be painted and information necessary for the painting operation are displayed; The painting operation management device: A film thickness pattern table that stores information on film thickness patterns associated with painting conditions; A painting condition table that stores the painting time, the painting conditions at the painting time, the position and posture of the painting gun at the painting time, and the film thickness pattern in association with each other; A painting gun movement speed table that stores the speed of the painting gun at a certain time; Holds a film thickness result table that stores the painting time, coordinate values, and film thickness formation pattern in association with each other; The step of the painting operation management device storing the painting conditions at the painting time and the position and posture of the painting gun at the painting time in the painting condition table; The step of the painting operation management device selecting a film thickness pattern based on the film thickness pattern table, the painting conditions at the painting time stored in the painting condition table, and the position and posture of the painting gun at the painting time; The step of the painting operation management device calculating the movement speed of the painting gun at the painting time and storing it in the painting gun movement speed table; The step of the painting operation management device integrating the film thickness values indicated by the selected film thickness pattern based on the speed of the painting gun at a certain time stored in the painting gun movement speed table for a certain period of time, calculating the film thickness formation pattern and the coordinate values of the film thickness formation pattern, and storing the painting time, coordinate values, and film thickness formation pattern in the film thickness result table in association with each other; The coating operation management device edits display data for a head-mounted display that includes information regarding the film thickness values indicated by the film thickness formation pattern, and outputs the data to the head-mounted display. The film thickness pattern is the film thickness value of the paint formed per unit time in each unit cell. A coating operation management method, characterized in that for each of the x-direction and y-direction of the surface of the object to be coated, the film thickness value indicated by each unit cell of the film thickness pattern is multiplied by a coefficient obtained by dividing the size of one side of the unit cell by the moving speed of the coating gun in the x-direction, and by a coefficient obtained by dividing the size of one side of the unit cell by the moving speed of the coating gun in the y-direction, and the integrated value for a certain period for each increment of time is used as the film thickness value indicated by each unit cell of the film thickness formation pattern.

Images