Fluid coating apparatus and fluid coating method

Abstract

To provide a method that enable efficient application of fluid to a plurality of small-size components or the like in a short time, using an intermittent method, while correcting excess and deficiency of application amounts and deviations of an application area or the like.SOLUTION: A fluid application device is provided, comprising: an applying portion that includes a fluid ejecting unit that ejects fluid to a plurality of application-target members, an ejected fluid property adjusting unit that adjusts a property of fluid ejected from the fluid ejecting unit and a fluid supply unit that supplies fluid to the fluid ejecting portion; a driving portion that includes an applying portion moving unit that moves a position of the applying portion and an application-target member conveying unit that conveys the application-target member; an inspecting portion that includes an imaging unit that images an application pattern of the application-target member, and a determining unit that determines whether the imaged application pattern is acceptable or not; and a control portion that includes a memory unit and a control unit that controls the applying portion, the driving portion and the inspecting portion.SELECTED DRAWING: Figure 5

Description

Technical Field

[0005] ,

[0004] , ,

[0001] The present invention relates to an apparatus and method for applying a fluid such as an adhesive or a paint to a coated member. In particular, the present invention relates to an apparatus and method for applying a fluid to a plurality of coated members using an injection device such as a coating gun.

Background Art

[0002] Conventionally, a method of continuously applying a fluid such as an adhesive or a paint to a plurality of small parts has been known. One aspect of a conventional method of applying a fluid to a plurality of parts will be described using FIGS. 1 to 3.

[0003] FIG. 1 is a top view and a perspective view of a coated member 110 to which a fluid is applied. For the sake of simplicity, the coated member 110 is a rectangular parallelepiped, and the coating surface 120 for applying the fluid is represented by the hatched portion on the upper surface. The periphery 130 around the coating surface 120 may have a peripheral portion that is not intended to be coated with the fluid. Here, although the peripheral portion is not intended to be coated with the fluid, a part of the fluid applied to the coating surface 120 may adhere thereto.

[0004] <� FIG. 2 is a schematic view showing a mode of applying the fluid 220 collectively to a plurality of coated members 110. First, with the coating surface 120 of the coated member 110 facing upward, a plurality of coated members 110 are arranged in a straight line. Then, the fluid 220 is ejected from above by a coating gun 210 or the like within a required range. When the application to one coated member 110 is completed, the position of the coating gun 210 is moved in the direction of the arrow, or the coated member 110 is moved by a conveyor or the like so that the ejection port of the coating gun 210 is disposed above another coated member 110. Thereafter, the fluid 220 is ejected from the coating gun 210, so that the fluid is applied to another coated member 110, and the above movement is repeated.

[0005] Such a method of applying a fluid is classified into a continuous method and an intermittent method. The continuous method is a method in which, once the fluid is ejected from the coating gun 210, the fluid is continuously applied to all the coated members 110 while changing the relative position of the coating gun 210 and the coated members 110 without stopping the ejection of the fluid.

[0006] Figure 3 is a schematic diagram representing a continuous coating method. In Figure 3, the arrows indicate the movement of the coating gun 210 (Figure 2), and the coating gun 210 moves along these arrows while continuously spraying fluid. The area 320 enclosed by the dashed line indicates the area to which the fluid is applied. In this continuous coating method, the fluid is continuously sprayed into the gaps between the members to be coated 110 and into areas where the members to be coated 110 are not lined up. As a result, not only is there waste in the consumption of fluid, but paint is also applied to the pallet 310 on which the members to be coated 110 are placed. Therefore, it becomes difficult to reuse the pallet 310, and it must be replaced after each coating, which complicates the coating process itself.

[0007] On the other hand, there is also an intermittent method in which the fluid is selectively ejected onto the coating surface of the member to be coated 110, rather than continuously ejecting the fluid. In this case, problems such as wasted fluid consumption and ejection to unintended areas, which occur in the continuous method, do not occur. However, in the intermittent method, the fluid ejection situation is unstable because the operation of stopping and restarting the ejection of fluid from the coating gun onto the coating surface 120 on the member to be coated 110 is repeated, making it difficult to accurately control the position and amount of fluid ejected. Consequently, there is a tendency for problems such as misalignment of the coating position, excess or insufficient coating amount, and unevenness to occur.

[0008] Patent Document 1 describes a method for spraying a coating material from a spray gun onto a moving object to be coated, which involves comparing a preset setting for the coating time for opening and closing the spray gun with actual coating time information obtained from a sensor for monitoring the spray coating state, calculating a deviation value of the actual coating time from the set value, and correcting the positional deviation. [Prior art documents] [Patent Documents]

[0009] [Patent Document 1] Japanese Patent Application Publication No. 10-244211 [Overview of the project] [Problems that the invention aims to solve]

[0010] While the method described in Patent Document 1 can correct for the difference between the set time and the actual coating time, it cannot address the excess or deficiency of the coating amount or the misalignment of the coating area that may occur when an intermittent method like the present invention is adopted.

[0011] The object of the present invention is to provide a method for efficiently coating multiple small parts, etc., in a short time, by using an intermittent method (in which a portion of the area where the coated members are placed is selected and the fluid is applied), while correcting for excess or insufficient coating amount and misalignment of the coating area. [Means for solving the problem]

[0012] A fluid coating apparatus according to one embodiment of the present invention includes a coating section that includes a fluid ejection unit for ejecting fluid onto a plurality of members to be coated, an ejection property adjustment unit for adjusting the properties of the fluid ejected from the fluid ejection unit, and a fluid supply unit for supplying fluid to the fluid ejection section; a drive unit that includes a coating section movement unit for changing the position of the coating section and a member to be coated transport unit for transporting the member to be coated; an inspection section that includes an imaging unit for imaging the coating pattern of the member to be coated and a determination unit for determining whether the imaged coating pattern is acceptable or not; a control unit that controls the coating section, the drive unit, and the inspection section, and a storage unit.

[0013] One embodiment of the fluid coating method in the present invention includes applying a fluid to a member to be coated, generating an image of the coating pattern of the fluid applied to the member to be coated, calculating the difference between the image and a predetermined reference coating pattern image, and applying the fluid to another member to be coated under conditions corrected for the difference. [Effects of the Invention]

[0014] According to the above aspect, in a method of intermittently applying a fluid such as an adhesive or a paint to a plurality of small parts or the like, it is possible to efficiently apply the fluid in a short time while correcting an excess or deficiency in the application amount and a deviation in the application area.

Brief Description of the Drawings

[0015] [Figure 1] It is a schematic diagram showing a member to be coated with a fluid in the prior art. [Figure 2] It is a schematic diagram showing a method of applying a fluid by a continuous method in the prior art. [Figure 3] It is a schematic diagram showing a method of applying a fluid by a continuous method in the prior art. [Figure 4] It is a schematic diagram showing the shape of a member to be coated with a fluid by a coating device according to an aspect of the present invention. [Figure 5] It is a schematic diagram of the whole of a coating device according to an aspect of the present invention. [Figure 6] It is a block diagram of the whole of a coating device according to an aspect of the present invention. [Figure 7A] It is a block diagram of a coating part of a coating device according to an aspect of the present invention. [Figure 7B] It is a block diagram of an ejection property adjustment unit according to an aspect of the present invention. [Figure 8] It is a schematic diagram showing a coating pattern by a coating device according to an aspect of the present invention. [Figure 9A] It is a schematic diagram showing an aspect of fluid coating by a coating device according to an aspect of the present invention. [Figure 9B] It is a schematic diagram showing an aspect of fluid coating by a coating device according to an aspect of the present invention. [Figure 10] It is a schematic diagram showing the steps of a coating method according to an aspect of the present invention. [Figure 11] It is a schematic diagram showing the whole fluid coating process of a coating method according to an aspect of the present invention. [Figure 12A]It is a schematic diagram showing the deviation of the coating pattern by the coating apparatus according to one aspect of the present invention. [Figure 12B] It is a schematic diagram showing the deviation of the coating pattern by the coating apparatus according to one aspect of the present invention. [Figure 13] It is a flowchart showing the inspection process of the coating method according to one aspect of the present invention. [Figure 14] It is a flowchart showing the inspection process of the coating method according to one aspect of the present invention.

Embodiments for Carrying out the Invention

[0016] Hereinafter, embodiments of one aspect of the present invention will be described with reference to the drawings. Note that the same elements are denoted by the same reference numerals, and the description may be omitted when the description overlaps. In the drawings, for easy understanding, each component is schematically shown mainly.

[0017] The drawings may schematically represent the width, thickness, shape, etc. of each part compared to the actual aspect for clearer explanation, but this is merely an example and does not limit the interpretation of the present invention.

[0018] In this specification, in the actual coating process, the vertically upward direction or a direction close to the vertically upward direction is referred to as "up" or "above", and "down" or "below" refers to the opposite direction of "up" or "above".

[0019] <Coated member> The coated member 110 to be coated using the fluid coating apparatus which is one aspect in the embodiment of the present invention will be described. An example of the coated member 110 that can be used in the present invention is shown in FIG. 4.

[0020] In the top view in FIG. 4, the shape of the coated member 110 is rectangular, and the part (hatched part) excluding the peripheral part 130 which is the lateral end becomes the coating surface 120 for coating the fluid. The cross-sectional view in Figure 4 shows the view when the A-A' plane in the top view is cut. Examples of the cross-sectional shape of the coated surface 120 include a semicircular recess (Pattern 1), a rectangular recess with the coated surface 120 at its bottom (Pattern 2), and a flat top surface without a recess where the coated surface 120 is a portion of the top surface (Pattern 3). However, the shape of the coated surface 120 is not particularly limited. For example, a protrusion may be formed on the top surface of the member to be coated 110 as the coated surface 120. In this way, the coated surface 120 on the member to be coated 110 can be set to any shape depending on the application of the fluid being applied, such as an adhesive or paint.

[0021] The fluid applied to the member to be coated 110 can be appropriately selected according to the application of the member to be coated 110, and can be, for example, an adhesive, paint, or lubricant. Examples of such fluids include epoxy resin, urethane resin, silicone resin, and acrylic resin, and can be used as solvents for these, such as xylene or asthoton.

[0022] The material constituting the coated member 110 can be appropriately selected depending on its compatibility with the fluid being applied and the application in which it will be used. For example, rubber, plastic, metal, ceramic, wood, etc., can be used. In addition to rubber bushings, the coated member 110 that can be used with the coating apparatus and coating method according to one embodiment of the present invention can be used with any material that is coated on one surface, such as metal or resin.

[0023] When the fluid is applied to the member to be coated 110, it is preferable to place and arrange the member to be coated 110 on a coating pallet in order to ensure stable positioning of the member to be coated 110 and to prevent the fluid from adhering to the coating apparatus itself. Known plate materials such as glass, metal, plastic, and wood can be used as the coating pallet.

[0024] In this specification, a rubber bushing that is bonded to a cylindrical shaft or the like will be used as a specific example to describe the coated member 110 having the cross-sectional shape of Embodiment 1.

[0025] <Overall configuration of the coating apparatus>

[0026] Figure 5 is a simplified schematic diagram showing the configuration of a coating apparatus according to one embodiment of the present invention. The coating apparatus according to one embodiment of the present invention includes a coating unit 520 having a coating gun, storage tank, piping, etc. for applying fluid to members 110 to be coated arranged at regular intervals, a drive unit 540 having a robot arm for changing the position of the coating gun and a conveyor (not shown) for transporting the members 110 to be coated, an inspection unit 560 having a camera for acquiring images of the members 110 to be coated with fluid and a computer for inspecting the coating pattern, and a control unit 500 having a computer for controlling these.

[0027] Figure 6 is a block diagram showing the configuration of each part included in a coating apparatus, which is one embodiment of the present invention. As explained in Figure 5, the coating apparatus has a coating unit 520 (indicated by the dashed line in Figure 5) which has a function related to the application of fluid, a drive unit 540 which has a function related to the movement and transport of the coating unit 520 and the member to be coated 110, and an inspection unit 560 which has a function related to the inspection of the coating pattern of the member to be coated 110 to which the fluid has been applied, and a control unit 500 which has a function related to the control of each of these parts. The configuration of each part will be described below.

[0028] <Coating section> The coating section 520 is a part that has the function of applying fluid to the member to be coated 110, and includes a fluid ejection unit 522 that ejects fluid toward the member to be coated 110, an ejection property adjustment unit 524 that adjusts the properties of the ejected fluid, such as the amount of fluid ejected, the ejection shape, and the distribution of the fluid, a fluid supply unit 526 that supplies fluid to the fluid ejection unit 522, and an air supply unit 528 that supplies air to the fluid ejection unit 522 for atomization during fluid ejection and for use during valve operation.

[0029] The configuration of the coating unit 520 will be explained using Figure 7A. Figure 7A is a block diagram showing the configuration of the coating unit 520 included in a coating apparatus according to one embodiment of the present invention.

[0030] The fluid to be applied to the member to be coated 110 is supplied from the fluid supply unit 526 to the fluid ejection unit 522. The fluid supply unit 526 mainly consists of a fluid storage tank installed inside or outside the coating device, and piping that sends the fluid from the storage tank to the vicinity of the fluid ejection unit 522. The piping may be structured to circulate the fluid, and the amount of fluid sent to the fluid ejection unit 522 can be adjusted by opening and closing the valve 650 (Figure 7A) connected to the piping.

[0031] Furthermore, during the fluid application process, air is required for atomizing the fluid when it is ejected and for operating valves that finely adjust the pressure and volume of the ejected fluid. This air is ultimately sent from the air supply unit 528 to the fluid ejection unit 522. The air supply unit 528, for example, takes compressed air circulating within the factory and sends it to an adjustment means such as the air controller 710 (Figure 7B), described later, by opening and closing the valve 660. This air supply unit 528 is used to individually control the flow rate and timing, for example, to operate the valve for the coating gun installed on the fluid ejection unit 522 (coating gun), or to atomize the fluid ejected from the coating gun.

[0032] The fluid ejection unit 522 is an injection device equipped with a nozzle for ejecting fluid, and a known coating gun for paint application can be used. The fluid ejection unit 522 ejects a mixture of fluid supplied from the fluid supply unit 526 and compressed air supplied from the air supply unit 528 onto the coating surface 120 of the member to be coated 110. Here, the amount of compressed air supplied from the air supply unit 528 to the fluid ejection unit 522 can be adjusted by opening and closing the valve 660.

[0033] The ejection property adjustment unit 524 has the function of controlling the coating pattern by adjusting the amount of fluid ejected from the fluid ejection unit 522, the ejection shape, the flow rate distribution, etc., based on instructions from the control unit 500 described later.

[0034] Figure 7B is a block diagram illustrating one embodiment of the ejection characteristic adjustment unit 524. To adjust the amount of fluid ejected, the ejection shape, and the flow rate distribution, it may be necessary to adjust the amount of air, the amount of fluid, and, in some cases, the shape of the nozzle tip. The ejection characteristic adjustment unit 524 can operate, for example, a coating gun valve attached to a coating gun, and an atomizing member for atomizing during ejection, via an air controller 710 connected to an air supply unit 528. Similarly, a flow rate adjustment valve can be operated by a fluid controller 720 connected to a fluid supply unit 526, and the nozzle shape can be controlled by a nozzle controller when a variable nozzle is used. Note that the coating gun valve, atomizing member, variable nozzle, and flow rate adjustment valve shown in Figure 7B are examples for adjusting the ejection characteristics of fluid and are not limited thereto.

[0035] The amount of fluid ejected from the fluid ejection unit 522 is adjusted by the ejection characteristics adjustment unit 524, specifically by a valve (not shown) that constitutes the ejection characteristics adjustment unit 524. In an embodiment of the present invention in which fluid is ejected intermittently, the ejection and stopping of fluid are repeated, requiring delicate responsiveness and flow rate control. Therefore, a valve that can adjust the amount of fluid ejected may be installed in the fluid ejection unit 522 at a position close to the nozzle.

[0036] The ejection shape and flow rate distribution of the ejected fluid depend on the shape of the nozzles constituting the fluid ejection unit 522 and the pressure and volume of the fluid and air at the time of ejection.

[0037] Figure 8 compares the fluid application patterns on the coating surface 120 of the member to be coated 110, with the dashed line representing the area 710 where the fluid is ejected and actually applied. In application method 1, the application pattern is circular when viewed from above, and if the coating surface 120 is rectangular, a large area of ​​coating is applied to unnecessary parts. In application method 2, the application pattern is elliptical, resulting in less excess coating area compared to application method 1. In application method 3, the fluid is ejected in a nearly rectangular application pattern, resulting in very little coating outside the coating surface 120.

[0038] Coating method 4 involves coating in a vertically elongated elliptical shape, but the fluid ejection unit 522 is moved horizontally for a certain period of time while continuously ejecting fluid for a short period. In this case, the fluid can be efficiently applied to the rectangular coating surface 120.

[0039] In this way, the nozzle shape of the fluid ejection unit 522 can be appropriately selected to match the pattern of the coated surface 120, and in some cases, the optimal coating pattern can be adjusted by moving the nozzle tip as in embodiment 4 above. As the nozzle, for example, known straight nozzles, flat nozzles, hollow cone nozzles, full cone nozzles, etc. can be used.

[0040] Furthermore, if the coating pattern needs to be adjusted frequently, a nozzle with a variable coating pattern and an adjustment mechanism may be used. In such cases, the coating pattern adjustment mechanism constitutes the ejection properties adjustment unit 524.

[0041] The amount of compressed air mixed in when the fluid is ejected is also an important factor in adjusting the coating pattern. In an intermittent fluid ejection configuration like the present invention, the fluid is ejected and stopped repeatedly, requiring precise control of the amount of compressed air. Therefore, a coating gun valve (Figure 7B) that can adjust the amount of compressed air used when the fluid is ejected may be installed in the fluid ejection unit 522.

[0042] In order to prevent unevenness in the applied fluid on the coated surface 120 of the coated member 110, it is preferable that the ejection behavior adjustment unit 524 can also adjust the flow rate distribution of the ejected fluid. The flow rate distribution can be adjusted by the nozzle shape and the air pressure during ejection, but if the coated surface 120 is a curved surface, it is necessary to adjust not only the air pressure when ejecting the fluid but also the orientation of the nozzle relative to the coated surface 120, and in some cases it is preferable that the unit be designed to allow ejection from multiple directions.

[0043] As described above, the ejection characteristic adjustment unit 524 is an adjustment mechanism for the nozzle and valve in the fluid ejection unit 522, and therefore may be integrated with the fluid ejection unit 522.

[0044] <Drive Unit> The drive unit 540 has functions related to the movement and transport of the coating unit 520 and the member to be coated 110, and is composed of a coating unit moving unit 542 that moves the fluid ejection unit 522 in the coating unit 520 in particular, and a member to be coated transport unit 544 that moves and transports the member to be coated 110.

[0045] Figure 9A is a schematic diagram showing an example of a coating unit moving unit 542 included in a coating apparatus according to one embodiment of the present invention. In Figure 9A, the coating unit moving unit 542 is a 6-axis robot arm 810, with a fluid ejection unit 522 installed at its tip.

[0046] By using the 6-axis robot arm 810, the degree of freedom in the direction of fluid ejection can be increased. For example, in Figure 9A, the fluid ejection unit 522 ejects fluid in a diagonal downward direction to the right. However, since the coated surface 120 of the coated member 110 has a semicircular cross-sectional shape, it is difficult to apply the fluid uniformly to the coated surface 120 if the application is from only one direction. Therefore, by ejecting the fluid once from a diagonal downward direction to the right, and then ejecting the fluid diagonally downward to the left, unevenness in the application on the coated surface 120 can be reduced.

[0047] Figure 9B shows an example where a 6-axis robot arm is not used. In Figure 9B, the members to be coated 110 are aligned on the pallet 310, but both the fluid ejection unit 522 and the pallet 310 are designed to move in the direction of alignment of the members to be coated 110. In this case, the fluid ejection unit 522 is moved by the coating unit moving unit 542, and when it reaches directly above the coating surface 120 of the members to be coated 110, the fluid can be ejected and coated.

[0048] Alternatively, the pallet 310 can be moved by the material to be coated transport unit 544 without moving the fluid ejection unit 522, and the fluid can be ejected and applied when the coating surface 120 of the material to be coated 110 reaches directly below the fluid ejection unit 522.

[0049] As described above, the application unit moving unit 542 in the fluid application process is not limited to a 6-axis robot arm. However, from the viewpoint of being able to select the optimal ejection direction according to the application surface 120, it is preferable to use a 6-axis robot arm 810.

[0050] Figure 10 is a schematic diagram illustrating the movement of the fluid ejection unit 522 and the coating unit moving unit 542 when applying fluid to the member to be coated 110.

[0051] In Figure 10, to apply fluid to the members to be coated 110 arranged at equal intervals on the coating pallet, the coating unit moving unit 542, which is composed of a 6-axis robot arm 810, moves the fluid ejection unit 522 at a constant speed in the direction of the dashed arrow. t1 represents the fluid ejection time when moving on the coating surface 120, t2 represents the time it takes to move between one coating surface 120 and another coating surface 120, and t3 represents the time required to move between different arrangements of the members to be coated 110.

[0052] In Figure 10, the fluid application pattern is a vertically elongated ellipse, as shown by the dashed line, and the fluid is sprayed from the left end to the right end of the application surface 120. When the fluid spraying unit 522 moves, the member to be coated A in Figure 10 is used as the starting position, and the unit sprays fluid while moving at speed V1 for a time t1. After time t1 has elapsed, the unit stops spraying fluid for a time t2 while moving at speed V2, and then resumes spraying fluid for another time t1 while moving again at speed V1. This operation can be repeated for the number of members to be coated 110 arranged horizontally.

[0053] Once the coating of the last member to be coated 110 in one array (member to be coated D in Figure 10) is complete, the fluid jetting stops for a time t3 at speed V3 as the unit moves to another array. Fluid jetting starts from the right end of the first member to be coated 110 in the other array (member to be coated E in Figure 10) for a time t1, and the fluid jetting and stopping are repeated while moving the fluid jetting unit 522 in the same manner as the first array.

[0054] The movement speeds V1 to V3 of the fluid ejection unit 522 may be the same or different. If the movement speed of the 6-axis robot arm 810 is adjustable, the speeds V2 and V3 during the times t2 and t3, when no fluid is ejected, may be set to high speeds.

[0055] In Figure 10, since the coating pattern is a vertically elongated ellipse, the fluid is continuously ejected onto the coating surface 120 for a duration of t1. However, by setting the coating pattern to cover a wider area, the fluid ejection unit 522 may be stopped while the fluid is ejected (as shown in coating modes 1-3 in Figure 2).

[0056] Furthermore, although Figure 10 shows the fluid being ejected to the coated member 110 in the order A, B, C, and D in a rightward direction, the coating order can be arbitrarily set when using a 6-axis robot arm 810. For example, coating may be performed in the order A, H, G, and B.

[0057] The material to be coated transport unit 544 can be used when applying fluid to the material to be coated 110, as described above, but it can also be used to transport the material to be coated 110 in the drying process and inspection process described later. The material to be coated transport unit 544 may be a conveyor that moves the pallet 310 on which the material to be coated 110 is arranged, or a 6-axis robot that moves the material to be coated 110 individually.

[0058] <Inspection Department> The inspection unit 560 has the function of inspecting the coating pattern of the coated member 110 to which the fluid has been ejected. The inspection unit 560 consists of an imaging unit 562 that captures and images the coating pattern of the coated member 110 to which the fluid has actually been applied or of a coating pattern confirmation jig used to correct the fluid ejection conditions, and a determination unit 564 that determines the difference between the captured image and a preset coating pattern sample.

[0059] Figure 11 is a schematic diagram showing the role of the inspection unit 560 in a coating apparatus according to one embodiment of the present invention. In Figure 11, the members to be coated 110, which are lined up on a pallet 310, are coated with fluid ejected from a fluid ejection unit 522 located at the tip of a 6-axis robot arm 810. The members to be coated 110, which have been coated with fluid, are transported together with the pallet 310 on a conveyor 1010. In Figure 11, an imaging unit 562-1 is positioned in one section of the conveyor, and the coating pattern of the fluid on the members to be coated 110 is captured and imaged.

[0060] Subsequently, the coated member 110 is sent to the drying process, where it is dried while being transported on the conveyor belt 1020. Once the applied fluid has dried, the imaging unit 562-2 captures and images the coating pattern formed on the coated member 110.

[0061] Here, the imaging units 562-1 and 562-2 can use commercially available cameras, video cameras, industrial cameras, etc.

[0062] Image data generated by the imaging unit 562-1 is sent to the determination unit 564-1, which is connected to the imaging unit 562-1 in a manner that enables data exchange. The determination unit 564-1 determines whether the difference between the coating pattern in the fluid coating process and a predetermined setting is acceptable, and transmits the determination result to the control unit 500.

[0063] Similarly, the image data generated by the imaging unit 562-2 is sent to the determination unit 564-2, which is connected to the imaging unit 562-2 in a manner that enables data exchange. The determination unit 564-2 determines whether the difference between the coating pattern of the fluid-coated member 110 manufactured through the drying process and a predetermined setting is acceptable, and transmits the determination result to the control unit 500.

[0064] The determination processes of determination units 564-1 and 564-2 will be explained below. Figures 12A and 12B are schematic diagrams illustrating an example of comparing a pre-set ideal coating pattern (hereinafter referred to as the reference coating pattern in this specification) with a coating pattern actually generated through the coating process. Here, the dashed line represents the reference coating pattern 1110, and the solid line represents the actually coated pattern 1120, with the images of both superimposed. Furthermore, Figure 12A shows a configuration in which the fluid ejection unit 522 does not move during coating (corresponding to embodiments 1 to 3 in Figure 8), while Figure 12B shows a configuration in which the fluid ejection unit 522 does move during coating (corresponding to embodiment 4 in Figure 8).

[0065] Figures 12A and 12B show the discrepancy between the reference coating pattern 1110 and the actual coating pattern 1120. Here, the parameters used to determine whether the discrepancy is acceptable are not particularly limited. For example, they could be the maximum difference in distance in the X, Y, or other directions between the solid and dashed lines, or the inclination angle of the pattern shape itself based on a predetermined direction.

[0066] Furthermore, if the coated surface 120 has a three-dimensional cross-section as shown in Embodiment 1 of Figure 4, it may be possible to detect unevenness in the fluid coating pattern. In that case, the unevenness during fluid coating can be determined by using data such as image contrast, color, and reflection of light irradiated from a fixed point.

[0067] The standard coating pattern is not particularly limited in its form, as long as it can be easily compared with the actual coating pattern when imaged. For example, an image of a approved sample of the coated member 110 that will actually be used may be used as the reference coating pattern. Alternatively, in order to create an image that makes it easier to distinguish differences in coating patterns, a jig for checking coating patterns may be created separately, and the fluid sprayed onto it and applied may be used as the reference coating pattern. In that case, in the fluid coating process shown in Figure 11, the fluid may be periodically applied to the jig for checking coating patterns, the pattern may be imaged by the imaging unit 562-1, and the judgment of the judgment unit 564-1 may be obtained by comparing it with the reference coating pattern.

[0068] The jig for verifying the coating pattern is not particularly limited as long as it allows for comparison of the coating pattern images. For example, a base sheet based on a predetermined standard may be used, and the coating may be applied to it under the same conditions as when the fluid is ejected onto the actual product.

[0069] In the determination unit 564-1's judgment, a certain threshold may be set for the deviation between the reference coating pattern and the actually coated pattern to be acceptable. That is, only if a deviation exceeding the threshold occurs between the reference coating pattern and the actually generated coating pattern, a determination result indicating that it is unacceptable can be sent to the control unit 500. In such a case, the control unit 500 may temporarily suspend a preset operation, such as the fluid coating process, or it may operate the ejection property adjustment unit 524 to fine-tune the ejection pressure, ejection volume, and ejection shape in the variable nozzle to approach the reference coating pattern without stopping the coating process.

[0070] The determination by the determination unit 564-2 is the same as the determination by the determination unit 564-2 and will therefore be omitted. However, if the coating pattern of the actually produced product deviates from the preset standard to an unacceptable degree, the measures that the control unit 500 can take may differ from those in the case of the determination unit 564-1 described above.

[0071] Figure 13 is a flowchart showing the inspection process in the process shown in Figure 11, illustrating the use of a jig for checking the coating pattern, separate from the coated member 110 used in the actual product, in order to verify the coating pattern.

[0072] In the coating section 520, during the coating process on the product, or interrupting the coating process on the product, the fluid is ejected into the coating pattern confirmation jig under the same conditions as when coating the product (S101).

[0073] The jig for checking the coating pattern, to which the fluid has been applied, is moved by a drive unit 540 such as a conveyor to a location where the imaging unit 562-1 can capture an image (S102). The imaging unit 562-1 then captures the coating pattern formed on the jig for checking the coating pattern (S103). The acquired image data is transmitted to the judgment unit 564-1.

[0074] The determination unit 564-1 compares the image data transmitted from the imaging unit 562-1 with pre-acquired reference coating pattern data (S104), calculates the difference between the two, and determines whether the pattern applied to the coating pattern confirmation jig is within an acceptable threshold range (S105).

[0075] If the pattern applied to the coating pattern confirmation jig is deemed acceptable (S105: acceptable), the coating pattern confirmation jig is ejected by the drive unit (S106), and production is started or continued (S107).

[0076] If the pattern applied to the coating pattern confirmation jig is deemed unacceptable, the determination result is transmitted to the control unit 500 (S105: Unacceptable). The control unit 500 either stops the coating process on the product or instructs the coating unit 520 to modify the conditions for spraying the fluid without stopping the coating process (S108). Upon receiving the modification instruction, the coating unit 520 modifies the fluid spraying conditions through the operation of the spraying properties adjustment unit 524.

[0077] The judgment unit 564-1 described above may use, for example, a commercially available computer. In this case, the software used for analyzing and judging the image pattern and the data for the reference coating pattern can be accessed by reading data stored in the storage unit 504 within the control unit 500.

[0078] Figure 14 shows the case where the coated member 110, which will be used as an actual product, is used to confirm the coating pattern.

[0079] The fluid is sprayed onto the material to be coated 110 (S201), dried, and then the drive unit 540 moves the imaging unit 562-2 to a location where it can capture an image (S202). The imaging unit 562-2 then captures the coating pattern formed on the material to be coated 110 (S203). The captured image data is transmitted to the determination unit 564-2.

[0080] The determination unit 564-2 compares the image data transmitted from the imaging unit 562-2 with the pattern data of a previously acquired approved product (S204), calculates the difference between the two, and determines whether the coating pattern formed on the coated member 110 is within an acceptable threshold range (S205).

[0081] If the coating pattern formed on the coated member 110 is deemed acceptable (S205: acceptable), the coated member 110 is shipped as a satisfactory product (S206) and production continues.

[0082] If it is determined that the coating pattern formed on the coated member 110 is unacceptable, the determination result is transmitted to the control unit 500 (S205: Unacceptable). The coated member 110 is discarded as a defective product (S207). The control unit 500 instructs either to stop the coating process on the product, or to modify the conditions for spraying fluid to the coating unit 520 without stopping the coating process (S208). Upon receiving the modification instruction, the coating unit 520 modifies the fluid spraying conditions through the operation of the spraying properties adjustment unit 524-2.

[0083] <Department Head> Returning to Figure 6, the control unit 500 will be described. The control unit 500 consists of a control unit 502 that controls the operation of the coating unit 520, the drive unit 540, and the inspection unit 560, and a storage unit 504 that stores the programs and data used to operate each of the above units.

[0084] The control unit 502 can, for example, control the coating pattern by operating the ejection properties adjustment unit 524 in the coating section 520 to adjust the flow rate of the fluid ejection, the air pressure, the shape of the variable nozzle, etc.

[0085] The memory unit 504 stores the programs necessary for driving the control unit 502 or each component. Furthermore, it stores data acquired by each component, such as the judgment results transmitted from the judgment unit 564, and data related to the aforementioned reference coating pattern, including image data of the reference coating pattern that serves as the basis for determining whether it is acceptable or not during the judgment.

[0086] The control unit 502 and the storage unit 504 may be a combination of a commercially available computer and memory, and it is preferable that they are capable of bidirectional data exchange between the coating unit 520, the drive unit 540, and the inspection unit 560.

[0087] <Variation> In the coating apparatus used in one embodiment of the present invention described above, the coated member 110 has a coating surface 120 facing vertically upward, but the coating surface 120 does not have to be positioned facing upward. For example, the coating surface 120 may face sideways or diagonally upward. However, if the coating surfaces 120 of each coated member 110 face different directions, the efficiency in the fluid coating process will decrease, so it is preferable that the coating surfaces 120 face the same direction at the stage when the fluid is applied.

[0088] In the coating apparatus described above as one embodiment of the present invention, the fluid ejection unit 522 used is controlled over a period of time t1 to t3 based on a preset travel speed (Figure 10). However, other factors besides time may also be considered, for example, the relative positional relationship between the fluid ejection unit 522 and the member to be coated 110 may be determined by image analysis, and the fluid may be ejected from the fluid ejection unit 522 at an appropriate position based on that positional relationship.

[0089] In the inspection step (flowcharts in Figures 13 and 14) of the coating method, which is one embodiment of the present invention described above, if the acceptance / rejection judgment (S105 in Figure 13, S205 in Figure 14) determines that the product is unacceptable, and the control unit 500 instructs the coating unit 520 to modify the coating conditions, the modification may be made automatically according to the instructions of the control unit 500, but is not limited to this. For example, the control unit 500 may display a modification instruction to the person in charge of the process, and the coating conditions of the control unit 500 may be modified manually or semi-automatically each time.

[0090] Based on one embodiment described herein, those skilled in the art may add, delete, or otherwise modify components as appropriate. Or designs that have been modified, or processes that have been added, omitted, or conditions changed. However, any other invention is included within the scope of the present invention, as long as it embodies the essence of the present invention.

[0091] Furthermore, any effects or benefits other than those brought about by one embodiment described herein, if they are clear from the description herein or easily predictable to a person skilled in the art, are naturally considered to be brought about by the present invention. [Explanation of symbols]

[0092] 110: Member to be coated, 120: Coating surface, 130: Peripheral area, 220: Fluid, 310: Pallet, 500: Control unit, 502: Control unit, 504: Memory unit, 520: Coating unit, 522: Fluid ejection unit, 524: Ejection property adjustment unit, 526: Fluid supply unit, Air supply unit 528, 540: Drive unit, 542: Coating unit movement unit, 544: Member to be coated transport unit, 560: Inspection unit, 562: Imaging unit, 564: Judgment unit, 650: Valve, 660: Valve, Air controller: 710, Fluid controller: 720, Nozzle controller: 730, 810: 6-axis robot arm, 1010: Conveyor, 1020: Conveyor

Claims

1. A fluid coating apparatus for intermittently applying fluid to a plurality of members to be coated arranged in a linear manner, A fluid ejection unit that ejects fluid onto a material to be coated in an elliptical coating pattern, A fluid ejection property adjustment unit for adjusting the properties of the fluid ejected from the fluid ejection unit, A fluid supply unit that supplies fluid to the aforementioned fluid ejection unit, A coating portion including, A coating unit moving unit that changes the position of the coating unit, A material transport unit for transporting the material to be coated, A drive unit including, An imaging unit that visualizes the coating pattern of the material to be coated, A judgment unit that determines whether the imaged coating pattern is acceptable or not, The inspection department, which includes, A control unit that controls the coating unit, drive unit, and inspection unit, Memory unit and A control unit including, Includes, The determination of whether or not it is acceptable is made based on the difference between the image of the coating pattern of the coated member that has been imaged and the image of a predetermined reference coating pattern, and the difference is the maximum value of the difference distance or the inclination angle. A fluid coating apparatus in which, if the control unit determines that the imaged coating pattern is unacceptable, the control unit causes the fluid to be applied to the plurality of coating members under modified conditions.

2. The fluid application apparatus according to claim 1, wherein the fluid ejection unit selects a portion of the area where the member to be coated is placed and applies the fluid.

3. The storage unit stores image data of the reference coating pattern that serves as the criterion for determining whether it is acceptable or not. The fluid coating apparatus according to claim 1, wherein the determination unit determines whether it is acceptable or not based on image data of the reference coating pattern.

4. The fluid coating apparatus according to claim 1, wherein the coating unit moving unit includes a 6-axis robot arm.

5. A fluid coating method for intermittently applying a fluid to a plurality of members to be coated arranged in a linear manner, The fluid is sprayed onto the multiple members to be coated in an elliptical coating pattern, An image of the coating pattern of the fluid applied to the coated member is generated. The difference between the aforementioned image and the image of a predetermined standard coating pattern is calculated. The aforementioned difference is either the difference in distance or the angle of inclination. Apply the fluid to the other multiple members to be coated under conditions corrected for the aforementioned differences. A fluid coating method that includes the following.

6. The fluid application method according to claim 5, wherein when applying a fluid to a member to be coated, a portion of the area where the member to be coated is placed is selected and the fluid is applied.

7. The fluid coating method according to claim 5, wherein the reference coating pattern is image data produced by coating a jig different from the member to be coated.

Images