Coating system

Abstract

This coating system comprises: a coating chamber module including a coating chamber frame, which is a frame member defining a first coating processing space in which a first coating-related operation related to coating is executed, and a coating robot that is disposed in the first coating processing space and executes the first coating-related operation; and a first transfer chamber module including a first transfer chamber frame, which is a frame member defining a conveyance work space, and a first transfer robot that is disposed in the conveyance work space and executes an operation of bringing a workpiece to be subjected to the first coating-related operation into the first coating processing space and / or an operation of taking the workpiece out of the first coating-related processing space. The coating chamber frame and the first transfer chamber frame are detachably connected to each other.

Description

Coating System

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

[0002] Patent Document 1 discloses an apparatus for semiconductor production equipment. This apparatus incorporates contrivances for easily providing additional functions to existing production equipment.

[0003] Japanese Patent Translation No. 2023-507098

[0004] A manufacturing line involving a coating operation is constructed according to the type of article to be coated and the coating operation process. Therefore, in order to operate a new manufacturing line, design and construction according to the type of article and the coating operation process are required. As a result, when the type of article and the coating operation process are different, the form of the manufacturing line also differs. That is, since a manufacturing line involving a coating operation is a so-called made-to-order product, it is necessary to go through a plurality of processes such as design, transportation, assembly, and testing from design to start of operation, and each process also requires a considerable amount of time.

[0005] Accordingly, the present invention provides a coating system capable of shortening the period until a manufacturing line involving a coating operation is put into operation.

[0006] A coating system according to one embodiment of the present invention includes a first coating module including a first coating frame, which is a frame member defining a first coating processing space in which a first coating-related operation regarding coating is executed, and a first coating processing unit disposed in the first coating processing space and executing the first coating-related operation, and a conveyance module including a conveyance frame, which is a frame member defining a conveyance work space, and a conveyance unit disposed in the conveyance work space and executing at least one of an operation of bringing an object to be the target of the first coating-related operation into the first coating processing space and an operation of taking the object out of the first coating processing space. The first coating frame and the conveyance frame are detachably connected to each other.

[0007] This coating system includes a first coating frame and a transport frame that can be detachably connected to each other. Therefore, at the location where the coating system is to be installed, the system can be set up by connecting the first coating frame and the transport frame and performing other incidental tasks. In other words, by providing a first coating frame and a transport frame that can be detachably connected to each other, the amount of work required at the installation location of the coating system can be reduced, thereby shortening the time it takes to get a manufacturing line that involves coating work up and running.

[0008] In the above coating system, when the first coating frame and the transport frame are connected to each other, the operating range of the transport unit may overlap with a part of the first coating processing space. With this configuration, the transport frame can bring the object to be coated into the first coating frame and remove the object to be coated from the first coating frame.

[0009] The above coating system further comprises a second coating frame, which is a frame member defining a second coating processing space in which second coating-related operations are performed, and a second coating module, which is arranged in the second coating processing space and includes a second coating processing unit that performs the second coating-related operations. When the second coating frame is connected to a transport frame, the operating range of the transport unit may overlap with a part of the second coating processing space in addition to a part of the first coating processing space. With this configuration, the object to be coated can be moved between the first coating module and the second coating module.

[0010] In the coating system described above, the first coating processing unit may be a coating device that sprays a coating material onto an object, and the second coating processing unit may be a drying device that dries the object to which the coating material has been sprayed. A coating system with this configuration can perform a drying operation.

[0011] In the coating system described above, the transport frame has a frame-shaped first transport frame connecting portion to which the first coating frame is connected, and a frame-shaped second transport frame connecting portion to which the second coating frame is connected. The shape of the first transport frame connecting portion when viewed from above may be the same as the shape of the second transport frame connecting portion when viewed from above. This configuration allows for greater flexibility in the connection configuration between the transport frame and the first coating frame.

[0012] The coating system described above further comprises a third coating frame, which is a frame member defining a third coating processing space in which a third coating-related operation is performed, and a third coating module, which is arranged in the third coating processing space and includes a third coating processing unit that performs the third coating-related operation. The third coating frame is connected to the first coating frame, and the third coating frame does not need to be connected to the transport frame. A coating system with this configuration can perform three operations related to coating.

[0013] In the coating system described above, the first coating processing unit is a coating device that sprays coating material onto an object, and the third coating processing unit may be a collection device that collects the atomized coating material ejected from the coating device. A coating system with this configuration can collect the atomized coating material.

[0014] In the coating system described above, the first coating module includes a first coating processing unit, which is a coating device that sprays a coating material onto an object, and a base on which the object is placed. The base may be positioned between the first coating processing unit and the third coating module when the coating material is being sprayed. A coating system with this configuration can suitably perform coating work and collection of atomized coating material.

[0015] The above coating system may further include a work module that includes a work frame, which is a frame member that defines a work area for the worker to handle the object. A coating system with this configuration can allow the worker to perform the work.

[0016] The coating system described above includes a clean area frame, which is a frame member that defines an area from which air is blown onto workers entering and exiting the work module, and may further include a cleanroom module connected to the work module. A coating system with this configuration can remove dust adhering to workers entering the work frame.

[0017] In the coating system described above, the transport unit may be an articulated robot. A coating system with this configuration can effectively transport the object to be coated.

[0018] In the coating system described above, the transport module may further include a moving mechanism for moving an articulated robot within the area defined by the transport frame. A coating system with this configuration can also suitably transport the object to be coated.

[0019] In the coating system described above, the first transport module, which is the transport module, includes a first movement mechanism, which is a movement mechanism for moving an articulated robot within a region defined by the first transport frame, which is the transport frame, and is connectable to the first transport frame. The second transport module further includes a second movement mechanism for moving an articulated robot within a region defined by the second transport frame, and the first rail constituting the first movement mechanism may be connected to the second rail constituting the second movement mechanism, so that the articulated robot can move between the first transport module and the second transport module. A coating system with this configuration can increase the degree of freedom in the transport method of the object to be coated.

[0020] According to the coating system of the present invention, the time required to start up a manufacturing line involving coating operations can be shortened.

[0021] Figure 1 is a perspective view showing a painting system, which is an example of an embodiment. Figure 2 is a perspective view showing a single frame with the internally housed equipment omitted from the illustration. Figure 3 is a perspective view showing a magnified corner of the frame shown in Figure 2. Figure 4 is a perspective view showing a magnified connection between the main frame and the subframe. Figure 5 is a perspective view showing the attachment / detachment chamber module. Figure 6 is a perspective view showing the dust removal / static elimination chamber module. Figure 7 is a perspective view showing the main configuration of the drive mechanism. Figure 8(a) is a plan view showing the drive mechanism in the first state. Figure 8(b) is a plan view showing the drive mechanism in the second state. Figure 8(c) is a plan view showing the drive mechanism in the third state. Figure 9 is a perspective view showing the painting chamber module. Figure 10 is a perspective view showing the first drying oven module. Figure 11 is a perspective view showing the first transfer chamber module. Figure 12 is a plan view of the first transfer chamber module, painting chamber module, dust removal / static elimination chamber module, and setting chamber module. Figure 13 is a perspective view showing the second transfer chamber module. Figure 14 is a plan view of the setting room module, the second transfer room module, and the first to third drying oven modules. Figure 15 is a perspective view of the cleanroom module. Figure 16 is a perspective view of the air supply room module. Figure 17 is a perspective view of the pump room module. Figure 18 is a perspective view of the control panel room module. Figure 19 is a perspective view of the setting room module. Figure 20 is a perspective view of the paint booth module.

[0022] Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the attached drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant explanations are omitted.

[0023] <Coating System> The coating system, which is an embodiment of this system, coats a predetermined material onto a workpiece 9 (object). One example of "coating" is so-called "painting," which involves spraying paint onto an object. In other words, the coating system shown in Figure 1 performs the process of spraying paint onto an object to be coated. Note that the coating system is not limited to painting processes and can be used for processes included in the concept of coating. In the following explanation, we will use "painting," which is an example of "coating," as an example. For example, "coating system" will be explained as "painting system 1," "object to be coated" will be explained as "object to be painted," and "coating operation" will be explained as "painting operation," etc.

[0024] Figure 1 is a perspective view showing a painting system 1, which is an example of an embodiment. The painting system 1 receives a workpiece 9, which is to be painted. The painting system 1 sprays a predetermined paint onto the received workpiece 9. After the paint sprayed onto the workpiece 9 dries, the painting system 1 passes it on to the next process.

[0025] The painting system 1 performs a painting operation in which a predetermined paint is sprayed onto the workpiece 9, as well as pre-treatment operations performed before the painting operation, post-treatment operations performed after the painting operation, and auxiliary operations performed incidentally to carry out these operations. Examples of pre-treatment operations include a dust removal operation to remove dust adhering to the surface of the workpiece 9 before painting, and an anti-static operation to eliminate the charged state of the workpiece 9. Examples of post-treatment operations include a drying operation to dry the paint sprayed onto the workpiece 9. Examples of auxiliary operations include a transfer operation to move the workpiece 9 and place it in a predetermined position.

[0026] The operations that the painting system 1 can perform are not limited to the examples given above. The painting system 1 can perform operations that are directly or indirectly related to the painting operation on the workpiece 9 as needed. In other words, the painting system 1 includes components for performing operations that are directly or indirectly related to the painting operation on the workpiece 9.

[0027] As shown in Figure 1, the painting system 1 has a configuration in which multiple frames having a common shape are interconnected. Inside each frame are devices for performing the functions related to the painting operation described above. The configuration including the frames and the devices housed within the frames is called a module. For example, one module can be considered to correspond to one or more functions related to the painting operation. In other words, the painting system 1 shown in Figure 1 performs the function of painting the workpiece 9 as a whole by combining multiple modules that perform predetermined functions.

[0028] The painting method varies depending on conditions such as the size and shape of the workpiece 9, and painting conditions such as whether the paint is sprayed once or multiple times. The painting system 1 can construct a painting line that satisfies these conditions by combining multiple modules that perform predetermined functions. One of the factors that enables such a highly flexible line construction is the frame mentioned above. Next, this frame will be described in detail.

[0029] <Frame> Figure 2 is a perspective view showing one frame 101, with the internal equipment omitted from the illustration. In the following description, it may be simply referred to as "frame 101," or it may be referred to individually as "painting room frame 231," etc., depending on the function of the module.

[0030] As shown in Figure 2, the frame 101 has a cubic main frame 11 and a rectangular subframe 12. In the example in Figure 2, the subframe 12, which has a smaller internal volume, is placed on top of the main frame 11, which has a larger internal volume. For example, equipment for painting operations, such as a painting robot, may be placed inside the main frame 11, which has a larger internal volume. Auxiliary equipment for the equipment placed on the main frame 11 may be placed inside the subframe 12, which has a smaller internal volume. Furthermore, the arrangement of the main frame 11 and the subframe 12 is not limited to that in Figure 2. For example, as shown in the drying oven frame 241 in Figure 10 later, it is also possible to place the subframe 12, which has a smaller internal volume, below the main frame 11, which has a larger internal volume.

[0031] The painting system 1 of this embodiment includes a frame 101 composed of a main frame 11 and a subframe 12 as shown in Figure 2, but is not limited to this configuration. The frame 101 includes at least a main frame 11, and the subframe 12 may be included as needed. Alternatively, the frame 101 may be an integrated unit of the main frame 11 and the subframe 12.

[0032] The multiple frames 101 provided by the painting system 1 do not need to have the same shape. The function of the frames 101 is to increase the degree of freedom in installing devices that perform predetermined functions and to facilitate their installation. Therefore, the shape of the frames 101 can be freely selected and changed within the range in which these functions can be performed. However, if the external shape of all the frames 101 provided by the painting system 1 is the same, the degree of freedom in installation is highest. Furthermore, the installation of the painting system 1 becomes easier. Accordingly, in the embodiment, we will explain assuming that the external shape of all the frames 101 provided by the painting system 1 is the same.

[0033] The main frame 11 is composed of eight main frame beam members 111 and four main frame column members 112. The main frame 11 has a cubic shape. The main frame 11 includes a bottom surface that is placed on the floor, a top surface that faces the ceiling, and four side surfaces. Of these, the four side surfaces are configured to be connectable to other main frame 11 modules. At each of the four corners, two main frame beam members 111 and one main frame column member 112 are connected to each other. Figure 3 is a perspective view showing an enlarged view of a corner. The main frame beam members 111 and main frame column members 112 have the same length and the same cross-sectional shape individually. In other words, when viewed as individual parts, there is no difference between the main frame beam members 111 and the main frame column members 112. The main frame column members 112 are formed by bending a metal plate.

[0034] The main frame column member 112 includes two mutually orthogonal main frame wall sections 115a and an auxiliary frame wall section 115b extending from the tip of the main frame wall section 115a. This cross-sectional shape, constructed by bending a metal plate, makes it possible to increase the bending rigidity (second moment of area), thereby ensuring the overall strength of the frame 101. Furthermore, cables such as power cables and communication cables for devices housed in the frame 101 can be accommodated in the area enclosed by the main frame wall section 115a and the auxiliary frame wall section 115b.

[0035] The cross-sectional shapes of the main frame beam member 111 and the main frame column member 112 can be considered to be roughly L-shaped. Therefore, the three members are connected by a connecting member 113 that includes a portion that conforms to this cross-sectional shape. For example, the main frame beam member 111 and the main frame column member 112 and the connecting member 113 may be fixed to each other by fastening members such as bolts and nuts.

[0036] Furthermore, Figure 4 is a magnified perspective view showing the connection point between the main frame 11 and the subframe 12. Figure 4 shows a connection configuration using cubic main frame connecting rectangular tubes 114 and subframe connecting rectangular tubes 124 instead of the connecting member 113 shown in Figure 3. Each connecting rectangular tube 114, 124 has four side wall portions 114a, 124a and two open ends 114s, 124s.

[0037] Each of the side walls 114a of the main frame connecting rectangular tube 114 is connected to a main frame beam member 111. A main frame column member 112 is connected to the open end 114s of the main frame connecting rectangular tube 114. Another open end of the main frame connecting rectangular tube 114 is connected to the end of the subframe connecting rectangular tube 124. Another end of the subframe connecting rectangular tube 124 is connected to the subframe column member 122. Each of the side walls 124a of the subframe connecting rectangular tube 124 is connected to a subframe beam member 121.

[0038] The painting system 1 has a painting module that is directly involved in the painting operation. The painting operation refers to an operation that directly affects the workpiece 9. The painting operation includes an operation to load the workpiece 9 (loading operation), an operation to remove dust from the workpiece 9 (dust removal operation), an operation to remove static electricity from the workpiece 9 (static removal operation), an operation to spray paint onto the workpiece 9 (painting operation), and an operation to dry the paint sprayed onto the workpiece 9 (drying operation).

[0039] <Loading / Unloading Chamber> Figure 5 is a perspective view showing the loading / unloading chamber module 21. The loading / unloading chamber module 21 is for the operation of loading / unloading the workpiece 9 as described above. The loading / unloading chamber module 21 receives the workpiece 9 before painting. More specifically, it receives the workpiece 9 transported from the equipment that performs the processing in the upstream process of the painting process. The loading / unloading chamber module 21 also unloads the painted workpiece 9 to the equipment that performs the processing in the downstream process. These receiving and unloading of workpiece 9 are collectively referred to as loading and unloading of workpiece 9. These receiving and unloading may be done manually by an operator, or automatically by a self-propelled transport robot with a driving function. The loading / unloading chamber module 21 is positioned adjacent to the dust removal / static elimination chamber module 22 and the second transfer chamber module 32, respectively. The loading / unloading chamber module 21 is composed of a loading / unloading chamber frame 211. The loading / unloading chamber module 21 may be equipped with a lighting device (not shown) and a work panel 212 as needed.

[0040] <Dust Removal and Static Elimination Chamber Module> Figure 6 is a perspective view showing the dust removal and static elimination chamber module 22 (second coating module). The dust removal and static elimination chamber module 22 is for the operation of removing dust from the workpiece 9 (dust removal operation: second coating-related operation) and the operation of removing static electricity from the workpiece 9 (static elimination operation: second coating-related operation) as described above. The dust removal and static elimination chamber module 22 is arranged adjacent to the attachment / detachment chamber module 21 and the first transfer chamber module 31. The dust removal and static elimination chamber module 22 consists of a dust removal and static elimination chamber frame 221 (second coating frame), a dust removal and static elimination chamber feeder 222, a dust removal device 223, and a static elimination device 224. The dust removal and static elimination chamber feeder 222 repeatedly rotates by a predetermined angle by a drive mechanism 6 including a cylinder, and then remains in standby mode. This operation improves the dust removal effect and static elimination effect.

[0041] Here, we will describe the drive mechanism 6 provided in the dust removal and static elimination chamber feeder 222. This drive mechanism 6 is also applicable to other modules described later. Figure 7 is a schematic diagram of the drive mechanism 6. As shown in Figure 7, the drive mechanism 6 consists of a pair of air cylinders 61 and 62 and a rotating disc 63. Each of the pair of air cylinders 61 and 62 uses compressed air as a driving source to reciprocate the pins 611 and 621. These pins 611 and 621 can also move in the axial direction using compressed air as a driving source. For example, in a configuration in which the pins 611 and 621 protrude, the pins 611 and 621 can be engaged with the rotating disc 63. In a configuration in which the pins 611 and 621 do not protrude, the pins 611 and 621 can be prevented from interfering with the rotating disc 63. In other words, the drive mechanism 6 drives the rotating disc 63 without using electricity like a motor. The pair of air cylinders 61 and 62 are arranged spaced apart from each other in a direction perpendicular to their respective driving directions. In other words, the pair of air cylinders 61 and 62 are arranged such that their respective driving directions are parallel to each other.

[0042] A shaft 64 is provided on the rotating disc 63, and this shaft is connected to the shaft of the dust removal and static elimination chamber feeder 222. Four grooves 631a, 631b, 631c, and 631d are formed on the rotating disc 63. The grooves 631a, 631b, 631c, and 631d are provided at equal intervals (90 degrees apart) around the central axis of the rotating disc 63. The grooves 631a, 631b, 631c, and 631d have openings on the outer circumferential surface of the rotating disc 63 and extend radially from the outer circumferential surface toward the central axis. The grooves 631a, 631b, 631c, and 631d penetrate from the front to the back surface of the rotating disc 63 and do not have a bottom surface. Pins 611 and 621 can be inserted into the grooves 631a, 631b, 631c, and 631d from the back side of the rotating disc 63.

[0043] Figure 8(a) is a plan view showing the state of the drive mechanism 6 in the first state. When in the first state, each of the first pin 611 and the second pin 621 does not fit into the grooves 631a, 631b, 631c, 631d. On the other hand, the first pin 611 is in a protruding form. The second pin 621 is in a non-protruding form.

[0044] Figure 8(b) is a plan view showing the state of the drive mechanism 6 in the second state. The first pin 611 and the second pin 621 are moved by the first air cylinder 61 and the second air cylinder 62 respectively. When the first pin 611 moves, it fits into the groove 631a. And when the first pin 611 continues to move, a torque about the central axis acts on the rotating disk 63 due to the movement of the first pin 611. As a result, the rotating disk 63 rotates by a predetermined angle (90 degrees). On the other hand, since the second pin 621 is not protruding, it does not interfere with the rotating disk 63.

[0045] Figure 8(c) is a plan view showing the state of the drive mechanism 6 in the third state. First, the first pin 611 is switched from a protruding form to a non-protruding form. The second pin 621 is switched from a non-protruding form to a protruding form. Next, the first pin 611 and the second pin 621 are moved by the first air cylinder 61 and the second air cylinder 62 respectively. Since the second pin 621 is in a protruding form, it interferes with the rotating disk 63. Specifically, the second pin 621 fits into the groove 631b. And when the second pin 621 continues to move, a torque about the central axis acts on the rotating disk 63 due to the movement of the second pin 621. As a result, the rotating disk 63 rotates by a predetermined angle (90 degrees). On the other hand, since the first pin 611 is not protruding, it does not interfere with the rotating disk 63.

[0046] In this way, the drive mechanism 6 can rotate the rotary disk 63 by a predetermined angle by means of the linear movement of the first pin 611 and the second pin 621 by the air cylinders 61 and 62, and the switching between the forms of protruding and not protruding the first pin 611 and the second pin 621. The drive mechanism 6 using compressed air described here is particularly useful when it is desired to use a module with an explosion-proof specification that cannot use electricity. On the other hand, when an explosion-proof specification module is not required, it is also possible to use a motor instead of the drive mechanism using compressed air.

[0047] The angle by which the rotary disk 63 rotates in one operation can be arbitrarily set according to the configuration of the grooves 631a, 631b, 631c, and 631d. For example, three grooves may be arranged on the rotary disk 63 at intervals of 120 degrees around the axis. In this case, the rotary disk 63 can be rotated by 60 degrees at a time.

[0048] <Coating Chamber Module> Figure 9 is a perspective view showing the coating chamber module 23 (first coating module). The coating chamber module 23 is for the operation of spraying paint on the workpiece 9 (coating operation: first coating-related operation) described above. The coating chamber module 23 is arranged adjacent to the first transfer chamber module 31 and the coating booth module 46. For example, the coating chamber module 23 is composed of a coating chamber frame 231, a coating robot 232 (first coating processing unit), and a coating chamber feeder 233 (pedestal). The coating chamber module 23 may be provided with an air supply chamber for performing air supply from the side as required.

[0049] <First Drying Oven Module, Second Drying Oven Module, Third Drying Oven Module> Figure 10 is a perspective view showing the first drying oven module 24A. The number of drying oven modules in the coating system 1 may be one or more than two. The coating system 1 of this embodiment includes three drying oven modules 24A, 24B, and 24C. The three drying oven modules 24A, 24B, and 24C are each located in the outermost region of the coating system 1. In other words, at least one of the four side surfaces of the drying oven modules 24A, 24B, and 24C is not connected to another module.

[0050] The first drying oven module 24A is for drying the paint sprayed onto the workpiece 9 (drying operation). The configurations of the second drying oven module 24B and the third drying oven module 24C are the same as those of the first drying oven module 24A, so a detailed explanation is omitted. The first drying oven module 24A is positioned adjacent to the second transfer chamber module 32. The first drying oven module 24A is adjacent to the long side of the second transfer chamber module 32. The first drying oven module 24A consists of a drying oven frame 241, a drying oven workpiece holder 242, and a hot air circulation device 243. The drying oven workpiece holder 242 repeatedly rotates by a predetermined angle (120 degrees) by the drive mechanism 6 and then remains in standby mode. This operation makes it possible to shorten the drying time.

[0051] The time it takes for the drying oven work holder 242 to complete one rotation may correspond to the time required for the coating applied to the workpiece 9 to dry. Of the several operations performed in the painting system 1, this drying operation takes the longest time. Therefore, the drying oven work holder 242 is provided with multiple holder tables 244 along the shaft 245 on which multiple workpieces 9 are placed. Furthermore, by providing multiple drying oven modules 24 in the painting system 1, it is possible to balance the total time required for several operations performed before the drying operation with the time required for the drying operation, thereby preventing workpieces 9 from accumulating before the drying operation. As a result, an efficient painting process can be achieved. Moreover, by modularizing the drying oven modules 24, it is easy to create a painting process that matches the required drying time which varies depending on the paint. Furthermore, since workpieces 9 are transferred to multiple drying oven modules 24 by a single second transfer chamber module 32 (described later), it is possible to reduce the robot's downtime. In addition, space can be saved.

[0052] The painting system 1 has several transport modules that are not directly involved in the painting operation. These transport modules have the function of transporting the workpiece 9 from one painting module that performs the painting operation of one process to another painting module that performs the painting operation of the next process.

[0053] <First Transfer Chamber Module> Figure 11 is a perspective view showing the first transfer chamber module 31 (transport module). The first transfer chamber module 31 performs two functions. As its first function, the first transfer chamber module 31 transports the workpiece 9 from the dust removal and static elimination chamber module 22 to the painting chamber module 23. As its second function, the first transfer chamber module 31 transports the workpiece 9 from the painting chamber module 23 to the setting chamber module 45, which will be described later. The first transfer chamber module 31 is positioned adjacent to the dust removal and static elimination chamber module 22, the painting chamber module 23, and the setting chamber module 45. The first transfer chamber module 31 consists of a first transfer chamber frame 311 (transport frame) and a first transfer robot 312 (transport unit).

[0054] Here, the operating range of the first transfer robot 312 will be described. Figure 12 is a plan view of the first transfer chamber module 31, the painting chamber module 23, the dust removal and static elimination chamber module 22, and the setting chamber module 45. As shown in Figure 12, the first transfer robot 312 has a first transfer operating range A312 (transport work space) indicated by a dashed line. The first transfer operating range A312 indicates the range in which the workpiece 9 can be moved by the first transfer robot 312. In other words, the first transfer robot 312 can freely move and position the workpiece 9 within the area enclosed by the first transfer operating range A312.

[0055] This first transfer operation range A312 overlaps with the first transfer chamber space A311 enclosed by the first transfer chamber frame 311, and also overlaps with the adjacent painting chamber module 23, dust removal and static elimination chamber module 22, and setting chamber module 45. In other words, the workpiece movement operation performed by the first transfer chamber module 31 is not limited to the first transfer chamber space A311 defined by the first transfer chamber frame 311, but also extends to the adjacent painting chamber module 23, dust removal and static elimination chamber module 22, and setting chamber module 45. More specifically, for example, the first transfer chamber space A311 also overlaps with a part of the painting chamber space A231 (first coating processing space) defined by the painting chamber frame 231 of the adjacent painting chamber module 23. The first transfer chamber space A311 similarly overlaps with a portion of the dust removal and static elimination chamber space A221 of the dust removal and static elimination chamber module 22 and the setting chamber space A451 of the setting chamber module 45. With this configuration, the first transfer robot 312 can transfer the workpiece 9 located in the dust removal and static elimination chamber module 22 to the painting chamber module 23. Furthermore, the first transfer robot 312 can transfer the workpiece 9 located in the painting chamber module 23 to the setting chamber module 45. In this way, a single first transfer chamber module 31 can perform both the transfer from the dust removal and static elimination chamber module 22 to the painting chamber module 23 and the transfer from the painting chamber module 23 to the setting chamber module 45. As a result, the floor area required for the equipment used to transfer the workpiece 9 can be reduced.

[0056] <Second Transfer Chamber Module> Figure 13 is a perspective view showing the second transfer chamber module 32. The second transfer chamber module 32 transports the workpiece 9 from the setting chamber module 45 to one of the drying oven modules 24A, 24B, or 24C. The second transfer chamber module 32 is made up of three connected second transfer chamber frames 321A, 321B, and 321C. At least one of these three second transfer chamber frames 321A, 321B, and 321C is adjacent to one of the drying oven modules 24A, 24B, or 24C. Furthermore, at least one of these three second transfer chamber frames 321A, 321B, and 321C is positioned adjacent to the loading / unloading chamber module 21. With this arrangement of the second transfer chamber module 32, the workpiece 9 can be moved in the order of setting chamber module 45, first drying oven module 24A, and loading / unloading chamber module 21. The second transfer chamber module 32 consists of the second transfer chamber frames 321A, 321B, and 321C mentioned above, the second transfer robot 322, and the robot transport unit 323.

[0057] Similarly, the second transfer robot 322 also has a second transfer operation range A322, indicated by the dashed line in Figure 14. The second transfer operation range A322 can overlap with the setting chamber module 45, the first drying oven module 24A, the second drying oven module 24B, and the third drying oven module 24C, which are adjacent to the second transfer chamber module 32.

[0058] Here, we will explain how the second transfer operation range A322 differs from the first transfer operation range A312. As shown in Figure 12, the first transfer operation range A312 overlaps with the spaces A231, A221, and A451 of the adjacent painting room module 23, dust removal and static elimination room module 22, and setting room module 45, respectively. This overlap does not change over time, and the first transfer operation range A312 always overlaps with these spaces A231, A221, and A451. This is because the first transfer robot 312 that defines the first transfer operation range A312 does not move, and therefore the first transfer operation range A312 does not move either.

[0059] In contrast, the second transfer operation range A322 is movable. This is because the second transfer robot 322, which defines the second transfer operation range A322, is capable of reciprocating along the rail 323a that constitutes the robot transport unit 323. In other words, when transferring a workpiece 9 from one module to another, the timing at which the second transfer operation range A322 overlaps with the processing space of one module (for example, the space A451 of the setting room module 45) does not need to coincide with the timing at which the second transfer operation range A322 overlaps with the space of another module (for example, the processing space A241 of the first drying oven module 24A). First, at the first timing, the second transfer operation range A322 is in a state where it overlaps with the processing space A451 of the setting room module 45, and in this state, the second transfer robot 322 picks up the workpiece 9 in the setting room module 45. Then, at the second timing, the second transfer robot 322, which has picked up the workpiece 9, moves to a position where the second transfer operation range A322 overlaps with the space A241 of the first drying oven module 24A, which is the transfer destination. Then, at the third timing, the second transfer operation range A322 is in a state where it overlaps with the space A241 of the first drying oven module 24A, and in this state, the second transfer robot 322 places the workpiece 9 on the first drying oven module 24A. With this configuration, one second transfer chamber module 32 can transfer the workpiece 9 to multiple drying oven modules 24A, 24B, and 24C.

[0060] The painting system 1 has several painting-related modules that are not directly involved in the painting operation. These painting-related modules perform the functions necessary to carry out the painting operation.

[0061] <Cleanroom Module> Figure 15 is a perspective view showing the cleanroom module 41. The cleanroom module 41 removes dust and debris attached to workers and self-propelled transport robots attempting to enter the loading / unloading room module 21. The cleanroom module 41 is positioned adjacent to the loading / unloading room module 21. The cleanroom module 41 consists of a cleanroom frame 411 (clean area frame) and an air gun device 412.

[0062] <Air Intake Room Module> Figure 16 is a perspective view showing the air intake room module 42. The air intake room module 42 takes in air flowing into the painting room module 23. More specifically, the air intake room module 42 draws in outside air, filters the drawn-in air, and then supplies it to modules that require airflow. Therefore, the air intake room module 42 may be placed in a corner of the painting system 1 to facilitate the intake of outside air. Specifically, the air intake room module 42 does not need to have other modules connected to two of the four side surfaces of the air intake room frame 421, which will be described later. The air intake room module 42 is arranged in the same row as the painting booth module 46 and the painting room module 23. For example, the air intake room module 42 consists of an air intake room frame 421 and an air intake fan 422. The air intake fan 422 has a built-in filtration filter.

[0063] <Pump Room Module> Figure 17 is a perspective view showing the pump room module 43. The pump room module 43 has a local exhaust function. The pump room module 43 may also have an air supply function. The pump room module 43 is equipped with devices such as a paint pump for supplying paint. Furthermore, paint mixing operations may be performed in the pump room module 43. The pump room module 43 is located adjacent to the painting room module 23. For example, the pump room module 43 is composed of a pump room frame 431 and a local exhaust device 433.

[0064] <Control Panel Module> Figure 18 is a perspective view showing the control panel module 44. The control panel module 44 houses a controller 442 (control panel) for controlling the painting robot 232 (first coating processing unit), the first transfer robot 312, and the second transfer robot 322. In addition to the controller 442 for the robots, the control panel module 44 may also contain controllers 442 for controlling the operation of other modules that constitute the painting system 1. There are no particular restrictions on the location where the control panel module 44 is located. The control panel module 44 consists of a control panel frame 441 and the controller 442.

[0065] <Setting Room Module> Figure 19 is a perspective view showing the setting room module 45. The setting room module 45 is for securing the waiting time (setting time) set before and after painting work. In other words, the setting room module 45 can also be said to be a storage space for the workpiece 9. The setting room module 45 is arranged adjacent to the first transfer room module 31 and the second transfer room module 32, respectively. The setting room module 45 consists of a setting room frame 451, a setting holder 452, and an air circulation device 453. The setting holder 452 repeatedly rotates by a predetermined angle (for example, 120 degrees) by the drive mechanism 6 and then remains in a waiting state.

[0066] <Paint Booth Module> Figure 20 is a perspective view showing the paint booth module 46 (third coating module). The paint booth module 46, which is a so-called dry booth, collects the atomized paint (paint mist) generated in the painting chamber module 23. The paint booth module 46 comprises a paint booth frame 461, a filter 462, a collection device 463, and a plurality of blowers 464. The filter 462 removes coarse particles in the stage before collecting the paint mist. The first blower 464 circulates the air that has been blown from the air supply chamber module 42 and passed through the painting chamber module 23 and the collection device 463 back into the painting chamber module 23. The second blower 464 exhausts the air that has passed through the collection device 463 to the outside. The paint booth module 46 is positioned adjacent to the painting chamber module 23. More specifically, the paint booth module 46 is positioned downstream of the direction in which the painting robot 232 in the painting chamber module 23 sprays the paint mist. For example, the paint booth module 46 consists of a paint booth frame 461 (third coating frame), a filter 462, a collection device 463 (third coating processing unit), and a blower 464.

[0067] <Effects and Benefits> There are various challenges for a system that performs painting. The first challenge is, for example, reducing construction time, saving space, and reducing costs. The second challenge is, for example, ensuring the strength of each unit for unit manufacturing. The third challenge is, for example, making the rotating devices and robots placed in the space where painting work is performed explosion-proof. The fourth challenge is, for example, reducing the energy consumed by the painting system 1 (energy saving). Furthermore, the fifth challenge is, for example, reducing the man-hours required when installing the painting system 1 and reducing maintenance.

[0068] The coating system 1 of this embodiment can satisfy one or more of the above-mentioned problems by having the following configurations.

[0069] As a first configuration that satisfies the first objective, the painting system 1 of this embodiment employs a structure in which the frame is made of sheet metal and the wiring can be housed within the frame. Furthermore, in order to shorten the construction period at the site where the painting system 1 is installed, a configuration is adopted that allows the unit to be shipped with the internal equipment already installed. According to this first configuration, the construction period required for the installation of the painting system 1 can be shortened and space can be saved.

[0070] As a second configuration to satisfy the second objective, the painting system 1 of this embodiment incorporates a design for the sheet metal frame's bending shape and the selection of an appropriate sheet thickness. This second configuration reduces the cost required for manufacturing the frame. Furthermore, since the frame's shape can be freely formed, workability can be improved, and strength can be ensured.

[0071] As a third configuration that satisfies the third challenge, the painting system 1 of this embodiment employs a robot that meets explosion-proof specifications and uses an actuator powered by compressed air as a rotating device. With this third configuration, painting can be performed while meeting the required specifications.

[0072] As a fourth configuration that satisfies the fourth objective, the painting system 1 of this embodiment employs a configuration that minimizes transport work. This reduces the number of motors required to transport the workpiece 9. Furthermore, the painting system 1 of this embodiment employs a drying oven shelf type work holder. This reduces the area occupied by the drying oven, thus reducing the capacity of the heat source. Moreover, the painting system 1 of this embodiment employs a supply and exhaust circulation system. This reduces the capacity of the motor required for supplying air. Furthermore, the fourth configuration reduces the running costs required to operate the painting system 1. Furthermore, the fourth configuration reduces the amount of electricity used, thus reducing carbon dioxide emissions.

[0073] As a fifth configuration that satisfies the fifth objective, the painting system 1 of this embodiment employs a configuration that minimizes transport operations and simplifies the structure. As a result, the parts constituting the painting system 1 can be easily replaced. By making it easier to replace parts, the costs required for maintenance can also be reduced.

[0074] The painting system 1 that achieves the above-described problems, configuration, and effects can also be described as follows: The painting system 1 comprises a painting chamber frame 231, which is a frame member that defines a first painting processing space in which first painting-related operations are performed, and a painting chamber module 23 that includes a painting robot 232 that is arranged in the first painting processing space and performs the first painting-related operations; a transfer chamber frame 311, which is a frame member that defines a transfer work space, and a first transfer chamber module 31 that includes a first transfer robot 312 that is arranged in the transfer work space and performs at least one of the operations of bringing a workpiece 9, which is the target of the first painting-related operations, into the first painting processing space and taking the workpiece 9 out of the first painting-related processing space. The painting chamber frame 231 and the first transfer chamber frame 311 are detachably connected to each other.

[0075] Evaluating painting system 1 from a different perspective, painting system 1 can achieve five effects.

[0076] The first benefit is the minimization of transport operations. The transfer of the workpiece 9 is performed by the first transfer robot 312 and the second transfer robot 322. As a result, the possibility of abnormalities occurring during the transport of the workpiece 9 can be reduced, and the workload required for maintenance can also be reduced. Furthermore, the area required for the installation of the first transfer robot 312 and the second transfer robot 322 can be smaller than the area required for installing transport devices such as belt conveyors. As a result, space-saving effects can also be achieved.

[0077] The second advantage is its explosion-proof capability. The mechanisms that drive the dust removal and static elimination chamber feeder 222, the painting chamber feeder 233, the drying oven work holder 242, and the setting holder 452 use a drive mechanism 6 powered by compressed air. In other words, these feeders and holders do not use actuators powered by electricity. Therefore, they can meet the required explosion-proof specifications.

[0078] The third advantage is that the frame is constructed from sheet metal. The frame, which is a component of each module, can be manufactured by bending metal sheets. As a result, as shown in Figures 3 and 4, it is possible to create a shape that allows wiring to pass through the inside. Furthermore, bending metal sheets also has the effect of reducing the manufacturing cost and time of the frame.

[0079] The fourth benefit is the simplification of the construction work required for installation. When installing the painting system 1, each module can be transported from the manufacturing plant to the installation site. As a result, at the installation site, the painting system 1 can be installed by tasks such as module mounting, module connection, and wiring. In other words, the number of tasks required at the installation site is reduced, thus shortening the construction period.

[0080] The fifth effect is the freedom of combination. Each module is equipped with a frame as a component, and these frames have a common configuration. As a result, the conditions required for connecting modules to each other become more flexible, so the position of the modules can be freely changed within the range where the conditions are met. Consequently, it is possible to flexibly add new functions to the painting system 1 when it is first installed.

[0081] This disclosure includes the following components:

[0082] An example of the present disclosure is [1] "a coating system comprising: a first coating frame which is a frame member that defines a first coating processing space in which a first coating-related operation relating to coating is performed; a first coating module which is arranged in the first coating processing space and includes a first coating processing unit that performs the first coating-related operation; a transport frame which is a frame member that defines a transport work space; and a transport module which is arranged in the transport work space and includes a transport unit that performs at least one of an operation to bring an object to be subjected to the first coating-related operation into the first coating processing space and an operation to take the object out of the first coating processing space, wherein the first coating frame and the transport frame are detachably connected to each other."

[0083] An example of the present disclosure is [2] "the coating system according to [1] above, wherein, when the first coating frame and the transport frame are connected to each other, the operating range of the transport unit overlaps with a part of the first coating processing space."

[0084] An example of the present disclosure is [3] "the coating system according to [1] or [2] above, further comprising a second coating frame which is a frame member that defines a second coating processing space in which a second coating-related operation relating to coating is performed, and a second coating module which is arranged in the second coating processing space and includes a second coating processing unit that performs the second coating-related operation, wherein when the second coating frame is connected to the transport frame, the operating range of the transport unit overlaps with a part of the second coating processing space in addition to a part of the first coating processing space."

[0085] An example of the present disclosure is [4] "the coating system according to [3] above, wherein the first coating processing unit is a coating device that sprays a coating material onto an object, and the second coating processing unit is a drying device that dries the object onto which the coating material has been sprayed."

[0086] An example of the present disclosure is [5] "the coating system according to [3] or [4] above, wherein the transport frame has a frame-shaped first transport frame connecting portion to which the first coating frame is connected, and a frame-shaped second transport frame connecting portion to which the second coating frame is connected, and the shape of the first transport frame connecting portion in plan view is the same as the shape of the second transport frame connecting portion in plan view."

[0087] An example of the present disclosure is [6] "a coating system according to any one of [1] to [5] above, further comprising a third coating frame which is a frame member defining a third coating processing space on which a third coating-related operation relating to coating is performed, and a third coating module which is arranged in the third coating processing space and includes a third coating processing unit which performs the third coating-related operation, wherein the third coating frame is connected to the first coating frame, and the third coating frame is not connected to the transport frame."

[0088] An example of the present disclosure is [7] "the coating system according to [6] above, wherein the first coating processing unit is a coating device that sprays a coating material onto an object, and the third coating processing unit is a collection device that collects the atomized coating material ejected from the coating device."

[0089] An example of the present disclosure is [8] "the coating system according to [7] above, wherein the first coating module includes a first coating processing unit which is a coating device for spraying a coating material onto an object, and a base on which the object is placed, the base being positioned between the first coating processing unit and the third coating module when the coating material is sprayed."

[0090] An example of the present disclosure is [9] "the coating system according to any one of [1] to [8], further comprising a work module which includes a work frame which is a frame member that defines a work area for an operation in which an operator handles the object."

[0091] An example of the present disclosure is

[10] "the coating system according to [9], further comprising a cleanroom module connected to the work module, which is a clean area frame that defines an area for blowing air onto an operator entering and exiting the work module."

[0092] An example of the present disclosure is

[11] "the coating system according to any one of [1] to

[10] above, wherein the transport unit is an articulated robot."

[0093] An example of the present disclosure is

[12] "the coating system according to

[11] , further comprising a transport module for moving the articulated robot within a region defined by the transport frame."

[0094] An example of the present disclosure is

[13] "the coating system according to

[12] above, wherein the first transport module, which is a transport module, includes a first moving mechanism, which is a moving mechanism, for moving the articulated robot within a region defined by the first transport frame, which is a transport frame, and further comprises a second transport module, which is connectable to the first transport frame, and includes a second moving mechanism, for moving the articulated robot within a region defined by the second transport frame, wherein a first rail constituting the first moving mechanism is connected to a second rail constituting the second moving mechanism, so that the articulated robot can move between the first transport module and the second transport module."

[0095] Furthermore, this disclosure also includes the following examples of painting equipment that is completed by combining units that are modularized for each process. The coating equipment can be modified or expanded simply by rearranging the units. In addition, since the coating equipment is completed simply by combining units, the construction period can be reduced. Furthermore, the structure of the coating equipment can be simplified by eliminating the need for conveyors.

[0096] Another example of the present disclosure is [1] "Painting equipment capable of automatically performing painting work requiring multiple painting processes, comprising a plurality of painting units corresponding to each of the plurality of painting processes, and a robot unit arranged adjacent to the painting units, characterized in that the painting units and the robot unit are arranged adjacent to each other in a manner that allows them to be attached and detached." According to this example, the equipment can be modified or expanded simply by rearranging the units. Furthermore, since it can be completed simply by combining the units, the construction period can be reduced.

[0097] Another example of the present disclosure is [2] "the painting equipment according to [1] above, characterized in that a plurality of painting units are arranged adjacent to one robot unit in a manner that allows for attachment and detachment." This example allows for miniaturization.

[0098] Another example of the present disclosure is [3] "the painting equipment according to [1] above, characterized in that the robot unit can be positioned adjacent to the rail unit in a manner that allows it to be attached to the rail unit, and in a state in which the robot unit and the rail unit are positioned adjacent to each other in a manner that allows them to be attached to the rail unit, the rails for the movement of the robots of the plurality of robot units are connected to the rails of the rail unit, and the robots of the robot unit can also move inside the rail unit."

[0099] Another example of the present disclosure is [4] "The painting equipment according to [1] above, characterized in that the plurality of painting units include a painting chamber unit having a painting machine, and a booth unit positioned adjacent to the painting chamber in a manner that allows for attachment and detachment of the booth unit, the booth unit having a collection device for collecting mist generated during painting in the painting chamber."

[0100] Another example of the present disclosure is [5] "the painting equipment according to [1] above, characterized in that the painting machine comprises a sprayer for spraying paint and a base for arranging a workpiece to be sprayed with paint by the sprayer, the sprayer is arranged inside the painting chamber unit to spray paint toward the booth, and the base is located between the sprayer and the booth when the sprayer is spraying."

[0101] Another example of the present disclosure is [6] "Painting equipment according to [1] above, characterized in that it includes a detachable unit into which an operator enters and performs work, for attaching a workpiece to be painted and / or removing a painted workpiece."

[0102] Another example of the present disclosure is [7] "the painting equipment according to [6] above, characterized in that it has a clean room connected to the loading / unloading room for removing dust and debris from workers entering the loading / unloading room."

[0103] 1...Painting system (coating system), 9...Workpiece (object), 22...Dust removal and static elimination room module (second coating module), 23...Painting room module (first coating module), 31...First transfer room module (transport module), 41...Clean room module, 46...Painting booth module (third coating module), 221...Dust removal and static elimination room frame (second coating frame), 232...Painting robot (first coating processing unit), 233...Painting room feeder (base), 311...First transfer room frame (transport frame), 312...First transfer robot (transport unit), 411...Clean room frame (clean area frame), 461...Painting booth frame (third coating frame), 463...Collection device (third coating processing unit), A231...Painting room space (first coating processing space), A312...First transfer operation range (transport work space).

Claims

1. A coating system comprising: a first coating frame, which is a frame member defining a first coating processing space in which a first coating-related operation is performed; a first coating module, which is arranged in the first coating processing space and includes a first coating processing unit that performs the first coating-related operation; a transport frame, which is a frame member defining a transport work space; and a transport module, which is arranged in the transport work space and includes a transport unit that performs at least one of the operations of bringing an object to be subjected to the first coating-related operation into the first coating processing space and taking the object out of the first coating processing space, wherein the first coating frame and the transport frame are detachably connected to each other.

2. The coating system according to claim 1, wherein, when the first coating frame and the transport frame are connected to each other, the operating range of the transport unit overlaps with a part of the first coating processing space.

3. The coating system according to claim 1 or 2, further comprising: a second coating frame, which is a frame member defining a second coating processing space in which a second coating-related operation is performed; and a second coating module, which is arranged in the second coating processing space and includes a second coating processing unit that performs the second coating-related operation, wherein, when the second coating frame is connected to the transport frame, the operating range of the transport unit overlaps with a part of the second coating processing space in addition to a part of the first coating processing space.

4. The coating system according to claim 3, wherein the first coating processing unit is a coating device that sprays a coating material onto the object, and the second coating processing unit is a drying device that dries the object onto which the coating material has been sprayed.

5. The coating system according to claim 3, wherein the transport frame has a frame-shaped first transport frame connecting portion to which the first coating frame is connected, and a frame-shaped second transport frame connecting portion to which the second coating frame is connected, and the shape of the first transport frame connecting portion when viewed from above is the same as the shape of the second transport frame connecting portion when viewed from above.

6. The coating system according to claim 1, further comprising: a third coating frame, which is a frame member defining a third coating processing space on which a third coating-related operation is performed; and a third coating module, which is arranged in the third coating processing space and includes a third coating processing unit that performs the third coating-related operation, wherein the third coating frame is connected to the first coating frame, and the third coating frame is not connected to the transport frame.

7. The coating system according to claim 6, wherein the first coating processing unit is a coating device that sprays a coating material onto the object, and the third coating processing unit is a collection device that collects the atomized coating material ejected from the coating device.

8. The coating system according to claim 7, wherein the first coating module includes a first coating processing unit which is a coating device that sprays the coating material onto the object, and a base on which the object is placed, the base being positioned between the first coating processing unit and the third coating module when the coating material is sprayed.

9. The coating system according to claim 1, further comprising a work module including a work frame which is a frame member that defines a work area for work on the object by an operator.

10. The coating system according to claim 9, further comprising a cleanroom module connected to the work module, the cleanroom module being a frame member that defines an area for blowing air onto an operator entering and exiting the work module.

11. The coating system according to claim 1, wherein the transport unit is a multi-joint robot.

12. The coating system according to claim 11, wherein the transport module further includes a moving mechanism for moving the articulated robot within the area defined by the transport frame.

13. The coating system according to claim 12, wherein the first transport module, which is the transport module, includes a first moving mechanism, which is the moving mechanism for moving the articulated robot within a region defined by the first transport frame, which is the transport frame, and further comprises a second transport module, which is connectable to the first transport frame, and includes a second moving mechanism for moving the articulated robot within a region defined by the second transport frame, and the first rail constituting the first moving mechanism is connected to the second rail constituting the second moving mechanism, so that the articulated robot can move between the first transport module and the second transport module.

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