3D powder coating automation system

Abstract

The present invention relates to a 3D powder coating automation system in which AI technology is used to generate precise three-dimensional shapes for various types of objects to be coated and optimal coating paths related thereto, thereby improving the efficiency and quality of coating, and coating costs are calculated so that a quotation system and a quotation bidding method are used to construct a quotation platform for connecting ordering companies and contractor companies for coating work. The 3D powder coating automation system according to the present invention comprises: a mounting unit on which an object to be coated is mounted; a 3D camera for capturing the object to be coated that is mounted on the mounting unit; a 3D object recognition module for generating, on the basis of modeling data of the object to be coated and an image captured by the 3D camera, a three-dimensional shape of the object to be coated; a coating path generation module for generating an optimal coating path from the three-dimensional shape generated by the 3D object recognition module; a spray unit for spraying coating material onto the object to be coated; a robot unit for moving the spray unit along the optimal coating path generated by the coating path generation module; a transport unit for moving the mounting unit; and a verification module for verifying the three-dimensional shape generated by the 3D object recognition module and the optimal coating path generated by the coating path generation module.

Description

3D Powder Coating Automation System

[0001] The present invention relates to a 3D powder coating automation system that uses AI technology to generate precise three-dimensional shapes of various types of coating objects and optimal coating paths therefor to improve the efficiency and quality of coating, calculates coating costs, and has a quotation system and a quotation platform that connects the ordering company and the receiving company for coating work through a quotation bidding method.

[0002] Generally, powder coating is a coating method in which powder paint is sprayed onto the surface of an object and dried to protect the surface or form it into various colors.

[0003] When the structure of the object to be painted is simple, a painting process is possible in which a spraying unit automatically sprays paint onto the surface of the object without operator intervention.

[0004] However, when the structure of the object to be painted is complex, automation is difficult, and workers manually operate the spray unit to distribute and apply the paint to every nook and cranny of the object. Such manual painting results in inconsistent paint quality and slow painting speeds.

[0005] The reality is that workers avoid powder coating due to the generation of various hazardous substances, and a significant level of skill is required to uniformly spray and apply the paint to the surface of an object.

[0006] As such, due to the avoidance by workers and the high skill requirements involved, there is an urgent need for technology to automate powder coating; however, technology capable of automatically powder coating objects with complex structures has not yet been presented.

[0007] Meanwhile, when a 3D powder coating automation system is established, there is a need for an estimation system that automates the calculation of coating costs and an estimation platform for the 3D powder coating automation system that acts as an intermediary between coating companies that have established the 3D powder coating automation system and ordering companies that will commission the coating, thereby connecting ordering companies and winning companies for coating work through an online estimation bidding method.

[0008] For reference, prior art regarding powder coating includes registered patent 10-2160614 "Powder coating system" and registered utility model 20-0226448 "Powder coating system".

[0009] The present invention is an invention developed to solve the problems of the prior art as described above, and aims to provide a 3D powder coating automation system that has excellent coating quality, high efficiency, and reduced coating time by generating a three-dimensional shape of a coating target based on images captured by a 3D camera and modeling data, generating an optimal coating path for the three-dimensional shape using AI technology, and executing coating by moving a spray unit with a robot unit along the generated optimal coating path.

[0010] In addition, the purpose is to provide a 3D powder coating automation system in which an estimation system is established to calculate coating costs and provide an estimate using the optimal coating path generated by simulation in the 3D powder coating automation system.

[0011] The purpose is to provide a 3D powder coating automation system with a quotation platform that connects the ordering company and the receiving company for painting work through an online quotation bidding method.

[0012] The 3D powder coating automation system according to the present invention for achieving this purpose

[0013] A mounting unit on which an object to be painted is mounted;

[0014] A 3D camera that photographs a painting object mounted on the above-mentioned mounting unit;

[0015] A 3D object recognition module that generates a three-dimensional shape of a painting object based on modeling data of the painting object and an image captured by the 3D camera;

[0016] A painting path generation module that generates an optimal painting path from a three-dimensional shape generated by the above 3D object recognition module;

[0017] A spray unit that sprays paint onto an object to be painted;

[0018] A robot unit that moves the spraying unit according to the optimal painting path generated by the above painting path generation module;

[0019] A transfer unit for moving the above-mentioned mounting unit;

[0020] It comprises a verification module that verifies the three-dimensional shape generated by the above 3D object recognition module and the optimal painting path generated by the above painting path generation module.

[0021] And a lap time calculation unit that calculates a lap time using the optimal painting path generated by the above painting path generation module, and

[0022] A spray time calculation unit that calculates the spray time of the paint in the above-mentioned spray unit, and

[0023] The estimation system further comprises an estimation calculation unit that calculates costs using a lap type calculated by the lap time calculation unit and an injection time calculated by the injection time calculation unit.

[0024] A 3D upload unit that receives three-dimensional shape information regarding the object to be painted from the ordering company, and

[0025] A 3D verification unit that verifies the validity of three-dimensional shape information uploaded to the above 3D upload unit, and

[0026] A 3D download unit that downloads the three-dimensional shape information verified by the above 3D verification unit to a 3D powder coating automation system established at a coating company, and

[0027] An estimate collection unit that receives painting cost estimate data from 3D powder coating automation systems of painting companies that have downloaded three-dimensional shape information, and

[0028] The quotation platform further comprises a contractor selection unit that selects a contractor by analyzing quotation data collected in the above-mentioned quotation collection unit.

[0029] The above-described spraying unit comprises a tube for transporting paint and a female part that is screw-fastened to a male part of a connector provided at the end of the tube, and a spray nozzle for spraying paint onto a target object.

[0030] Each of the female part of the injection nozzle and the male part of the connector is provided with a threaded part having threads formed thereon and a non-threaded part not having threads formed thereon, and the female part is provided with a fastening rod having threads formed on its inner surface that can advance toward the non-threaded part.

[0031] The 3D powder coating automation system according to the present invention generates a precise three-dimensional shape for each of various types of coating objects, generates an optimal coating path based on the generated three-dimensional shape, and causes a spraying unit to move along the generated optimal coating path to spray paint, thereby enabling high-quality coating, excellent coating efficiency, and reduced coating time.

[0032] In addition, an estimation system is established that calculates and provides lap time and painting time using the optimal painting path generated by the 3D powder coating automation system, and calculates and provides an estimate for painting costs using the lap time and painting time, thereby enabling the delegator and the contractor of painting work to utilize the provided lap type and costs, etc., in their decision-making regarding delegation and acceptance.

[0033] As an online platform connecting clients and contractors for painting work, it enables clients to select competitive contractors through a quotation bidding process and assists contractors in recruiting, thereby establishing a win-win platform for both parties.

[0034] As a system, it is an invention that is very useful for industrial development.

[0035] FIG. 1 is a configuration diagram of an estimation platform for a 3D powder coating automation system according to the present invention.

[0036] FIG. 2 is a configuration diagram of a 3D powder coating automation system and an estimation system for the same according to the present invention.

[0037] FIG. 3 is a drawing illustrating the connection structure of a connector between a spray nozzle and a tube according to the present invention.

[0038] *Explanation of symbols for major parts of the drawing*

[0039] 10 : Mounting unit 20 : Transfer unit

[0040] 30 : 3D Camera 40 : 3D Object Recognition Module

[0041] 50 : Painting path generation module 60 : Spray unit

[0042] 70 ; Robot Unit 80 : Verification Module

[0043] 90 : Controller 100 : Scanner

[0044] 110 : Search Engine 120 : Modeling DB

[0045] CES : Estimation System 130 : Lab Time Calculation Unit

[0046] 140: Spray time annual unit 150: Washing time calculation unit

[0047] 160: Drying time calculation unit 170: Estimate calculation unit

[0048] 200 : Quote Platform 210 : 3D Upload Section

[0049] 220 : 3D Verification Section 230 : 3D Download Section

[0050] 240 : Estimate Collection Section 250 : Contractor Selection Section

[0051] Hereinafter, a quotation platform based on a 3D powder coating automation system according to the present invention will be described in more detail with reference to the drawings.

[0052] As shown in FIG. 1, the quotation platform (200) for the 3D powder coating automation system according to the present invention includes a 3D upload unit (210), a 3D verification unit (220), a 3D download unit (230), a quotation collection unit (240), and a contractor selection unit (250).

[0053] The above 3D upload unit (210) receives three-dimensional shape information regarding the object to be painted from ordering companies. At this time, in addition to the three-dimensional shape information, it also receives information such as the quantity of the object to be painted, the type of paint, color, and coating thickness.

[0054] The 3D verification unit (220) verifies the validity of the three-dimensional shape information uploaded to the 3D upload unit (210). That is, it verifies whether the uploaded three-dimensional shape information can be used in the 3D powder coating automation system (PCS1, PCS2, PCS3) and verifies whether there are any problems with other information other than the three-dimensional shape information. If it is determined to be valid as a result of the verification, it is transferred to the 3D download unit (230).

[0055] The above 3D download unit (230) downloads the three-dimensional shape information verified by the above 3D verification unit (220) to the 3D powder coating automation system (PCS1, PCS2, PCS3) built in the coating company.

[0056] The 3D powder coating automation system (PCS1, PCS2, PCS3) of the coating company is equipped with an estimation system (CES1, CES2, CES3) to calculate the cost required to coat an object based on downloaded three-dimensional shape information and generate estimation data.

[0057] The above-mentioned estimate collection unit (240) receives painting cost estimate data from the 3D powder coating automation systems (PCS1, PCS2, PCS3) of painting companies that have downloaded three-dimensional shape information.

[0058] The above-mentioned contractor selection unit (250) analyzes the quotation data collected by the above-mentioned quotation collection unit (240) to select a contractor to handle the painting work and notifies the relevant ordering company.

[0059] The above-mentioned contractor selection unit (250) selects a contractor by considering not only the painting costs of the quotation data, but also various requirements requested by the ordering company and whether the painting company accepts them.

[0060] Figure 2 illustrates an example of a 3D powder coating automation system (PCS; Power Coating System) established in a coating company and a cost estimation system (CES; Cost Estimation System) based thereon.

[0061] The above 3D powder coating automation system (PCS; Power Coating System) comprises a mounting unit (10), a transfer unit (20), a 3D camera (30), a 3D object recognition module (40), a coating path generation module (50), a spraying unit (60), a robot unit (70), a verification module (80), a controller (90), and a cost estimation system (CES; Cost Estimation System) based thereon is broadly divided into components of a lap time calculation unit (130), a spray time calculation unit (140), a washing time calculation unit (150), a drying time calculation unit (160), and a cost calculation unit (170).

[0062] The above mounting unit (10) is used to mount an object to be painted. There are no specific restrictions on where the mounting unit (10) holds the object to be painted (1) and in which direction it mounts it, but the mounted object to be painted (1) must not shake during the painting process, the contact area between the mounting unit (10) and the object to be painted (1) must be minimized, and the mounting unit (10) must minimize interference with the movement of the robot unit (70).

[0063] The above transfer unit (20) transfers the above mounting unit (10). The above transfer unit (20) may include a gear or pulley arranged on both sides, a transfer rail coupled to the mounting unit (10) and circulating along the gear or pulley on both sides, and a motor that rotates one of the gear or pulley on both sides.

[0064] A scanner (100) for checking whether a painting object is mounted on the mounting unit (10) may be placed at the entrance side of the above-mentioned transfer unit (20).

[0065] The above 3D camera (30) photographs the object to be painted (1) mounted on the above mounting unit (10).

[0066] The image captured by the 3D camera (30) is a 3D stereoscopic image, which can identify the shape of the object to be painted, that is, the type of object to be painted. The image captured by the 3D camera (30) is transmitted to a search engine (110), and the search engine (110) searches the modeling DB (120) to extract modeling data corresponding to the object to be painted in the image. Modeling data for various types of objects to be painted is stored in the modeling DB (120).

[0067] The image captured by the above 3D camera (30) is used not only to identify the type of object to be painted, but also to monitor the painting process and the quality of the painting.

[0068] The above 3D camera (30) can be installed in various places along the transport direction of the above transport unit (20).

[0069] The above 3D object recognition module (40) generates a three-dimensional shape of a painting object based on modeling data of the painting object extracted through the search engine and an image captured by the 3D camera (30). It analyzes the image captured by the 3D camera (30) to obtain information regarding the position and orientation of the painting object mounted on the mounting unit (10), and generates a three-dimensional shape based on the modeling data according to the acquired position and orientation.

[0070] The above-mentioned painting path generation module (50) generates an optimal painting path from the three-dimensional shape generated by the above-mentioned 3D object recognition module (40). AI technology is utilized to generate the optimal painting path. The optimal painting path refers to the distance between the spray nozzle (610) and the object to be painted, the spray angle of the spray nozzle (610), the movement path of the spray nozzle (610), etc., which influence increasing painting speed while increasing painting quality and efficiency.

[0071] Paint is sprayed onto the surface of the object to be painted using the above spray unit (60).

[0072] The above-mentioned spraying unit (60) includes a spray nozzle (610) for spraying paint, a paint tank for holding paint, a tube (620) connecting the paint tank and the spray nozzle (610), and a compressor that supplies the paint from the paint tank to the spray nozzle (610) through the tube (620) and sprays it.

[0073] The robot unit (70) moves the spray unit (60) along the optimal painting path generated by the painting path generation module (50).

[0074] The above robot unit (70) may be configured as a rail type consisting of frames that are transported along the X-axis, Y-axis, and Z-axis, respectively, or as an articulated type consisting of arms that can rotate in at least one direction, and a combination of the rail type and the articulated type may be applied.

[0075] If the entire object to be painted is painted using a single spray unit (60) and a robot unit (70), it may take a long time and be inefficient. Therefore, it may be desirable to install multiple spray units (60) and robot units (70) along the transfer unit (20). Each of the multiple spray units (60) and robot units (70) paints a portion of the object to be painted, and the painting is completed at the spray unit (60) and robot unit (70) placed last.

[0076] The verification module (80) verifies the stereoscopic image generated by the 3D object recognition module (40) and the optimal painting path generated by the painting path generation module (50). The accuracy of the stereoscopic image and the optimal painting path determines the quality of the painting. Therefore, the stereoscopic image and the optimal painting path are continuously verified during the painting process, and if an error occurs as a result of the verification, it is corrected.

[0077] The above controller (90) generally controls the quotation platform based on the 3D powder coating automation system according to the present invention.

[0078] For example, the scanner (100) checks whether the object to be painted (1) is mounted on the mounting unit (10), monitors whether the painting process is being carried out normally from the image captured by the 3D camera (30), and controls the spray unit (60) and the robot unit (70) according to the three-dimensional shape of the object to be painted (1) and the optimal painting path so that painting is performed on the object (1). Then, the drying room for drying the painted object and the washing room for washing are controlled.

[0079] As the spray nozzle (610) of the above-mentioned spray unit (60) repeatedly sprays paint, hardened paint or foreign substances adhere to the exit of the flow path of the spray nozzle (610), and then the paint cannot be sprayed uniformly, resulting in a decrease in painting quality.

[0080] Therefore, the spray nozzle (610) is replaced frequently, and the used spray nozzle (610) is cleaned and prepared so that it can be replaced.

[0081] The above injection nozzle (610) is connected to a connector (630) provided at the end of the tube (620) by a screw method.

[0082] A spraying section (611) for spraying paint is provided at the front of the above-mentioned spray nozzle (610), and an arm connection section (612) is provided at the rear to allow the spray nozzle (610) to be rotated with a tool such as a wrench. The outer surface of the above-mentioned arm connection section (612) is formed in an octagonal structure.

[0083] The front of the connector (630) is provided with a male connecting part (632) that is screw-fastened to the female connecting part (612), the rear is provided with a connecting part (631) to which a tube (620) is connected, and between the male connecting part (632) and the female connecting part (612), an octagonal supporting part (633) is provided.

[0084] On the inner surface of the flow path (613) of the female connection part (612) of the injection nozzle (610) and the outer surface of the male connection part (632) of the connector (630), threaded portions (614, 634) with threads and non-threaded portions (615, 635) without threads are alternately formed. At this time, four of the threaded portions (614, 634) and non-threaded portions (615, 635) are formed to match an octagonal structure.

[0085] When the screw portion (634) of the male connection part (632) is aligned with the non-screw portion (615) of the female connection part (612), and the spray nozzle (610) is pushed toward the connector (630), the male connection part (632) is inserted into the flow path (613) of the female connection part (612) without obstruction. Subsequently, by rotating the spray nozzle (610) one or two turns, the connection between the spray nozzle (610) and the connector (630) is completed.

[0086] Here, when the spray nozzle (610) is rotated, the threaded portion (614) of the female connection part (612) must enter the threaded portion (634) of the male connection part (632). However, during the process of rotating the spray nozzle (610), after the threaded portion (614) of the female connection part (612) and the non-threaded portion (635) of the male connection part (632) align, the threaded portion (614) of the female connection part (612) is unable to enter the next threaded portion (634) of the male connection part (632), and consequently, a situation occurs in which the spray nozzle (610) rotates in place.

[0087] To solve this problem, the female connecting part (612) of the injection nozzle (610) is provided with a connecting rod (616) that can move back and forth toward the non-threaded part (615) of the flow path (613).

[0088] A fastening block (6161) is provided on the inner side of the fastening rod (616), and a screw thread (6162) is formed on the inner surface of the fastening block (6161). When the fastening rod (616) advances, a screw thread (6162) is formed on the non-screw portion (615) of the female fastening portion (612), so that the injection nozzle (610) is tightened to the connector (630) without rotating in place.

[0089] A push pin (6165) is connected to the outside of the above-mentioned fastening block (6161), and the push pin (6165) protrudes outward from the outer surface of the above-mentioned female fastening part (612). Two fastening rods (616) are provided facing each other, and when a tool such as a wrench that rotates the spray nozzle (610) is coupled to the above-mentioned female fastening part (612), the push pin (6165) is pressed by the tool, and the fastening rod (616) moves forward inward.

[0090] The arm connection part (612) of the injection nozzle (610) is rotatably provided with a rotor magnet (617), and the push pin (6165) of the connection rod (616) penetrates the rotor magnet (617). A magnet (6163) may also be provided on the outer side of the connection block (6161) of the connection rod (616). When the rotor magnet (617) is rotated so that the polarity of the rotor magnet (617) and the magnet (6163) of the connection block (6161) are different, an attractive force acts, causing the connection rod (616) to move backward outward, and when the polarity of the rotor magnet (617) and the magnet (6163) of the connection block (6161) are the same, a repulsive force acts, causing the connection rod (616) to move forward inward.

[0091] The spray nozzle (610) can be gradually released from the connector (630) due to the impact when paint is sprayed from the spray nozzle (610).

[0092] To prevent such loosening, fixing grooves (618) are formed on the rear surface of the female connection part (612) of the spray nozzle (610), and a fixing pin (638) is provided to move back and forth on the support part (633) of the connector (630). When the fixing pin (638) moves forward, it is inserted into the fixing groove (618) and catches, thereby preventing the spray nozzle (610) from rotating and thus preventing the spray nozzle (610) from loosening.

[0093] A movable block (637) is provided at the rear of the fixed pin (638), and the movable block (637) is made of a magnet. A movable groove (636) is formed in the support portion (633) of the connector (630) to allow the movable block to move back and forth. The movable block (637) moves forward and attaches to the support portion (633) on the front side to prevent the fixed pin (638) from being separated from the fixed groove (618).

[0094] A step is formed on the inner side of the flow path (613) of the female connection part (612) of the injection nozzle (610) to support a packing (640). The packing (640) is pressed tightly against the step and the end of the male connection part (632) of the connector (630) to seal the gap between them.

[0095] In order to increase the sealing power of the packing (640), the packing (640) has a structure in which the thickness decreases from the edge to the center, so that a sealing groove (641) is formed on the surface. When the packing (640) is pressed against the shoulder of the spray nozzle (610) and the end of the connector (630), the sealing groove (641) is pressed, and the air in the sealing groove (641) is discharged to the outside to create a vacuum, and accordingly, the packing (640) adheres more tightly to the shoulder and the end of the connector (630).

[0096] A figure-eight shaped plate spring (643) is embedded in the packing (640). The plate spring (643) prevents compression deformation of the packing (640), thereby increasing durability and strengthening and maintaining the sealing force through the sealing groove (641).

[0097] The above-mentioned estimation system (CES) calculates various times related to painting and calculates costs using the optimal painting path generated by the painting path generation module (50) of the above-mentioned 3D powder coating automation system.

[0098] The above-mentioned estimation system (CES) includes a lap time calculation unit (130) that calculates the lap time required to complete the painting of one object (1), a spray time calculation unit (140) that calculates the spray time of the paint (i.e., the amount of paint used), a washing time calculation unit (150) that calculates the spray time of the washing water (i.e., the amount of washing water used), a drying time calculation unit (160) that calculates the drying time of the paint and washing water, and an estimation calculation unit (170) that calculates the painting cost using the various calculated times, the quantity of objects to be painted, and other cost elements.

[0099] The various times and calculated painting costs derived from the above-mentioned quotation system (CES) are provided to the painting company and the client for use.

Claims

1. A mounting unit on which an object to be painted is mounted; A 3D camera that photographs a painting object mounted on the above-mentioned mounting unit; A 3D object recognition module that generates a three-dimensional shape of a painting object based on modeling data of the painting object and an image captured by the 3D camera; A painting path generation module that generates an optimal painting path from a three-dimensional shape generated by the above 3D object recognition module; A spray unit that sprays paint onto an object to be painted; A robot unit that moves the spraying unit according to the optimal painting path generated by the above painting path generation module; A transfer unit for moving the above-mentioned mounting unit; A 3D powder coating automation system comprising: a verification module that verifies a three-dimensional shape generated by the above 3D object recognition module and an optimal coating path generated by the above coating path generation module.

2. In Paragraph 1, A lap time calculation unit that calculates a lap time using the optimal painting path generated by the above painting path generation module, and A spray time calculation unit that calculates the spray time of the paint in the above-mentioned spray unit, and A 3D powder coating automation system further comprising: an estimation system including an estimation calculation unit that calculates a cost using a lap type calculated by the lap time calculation unit and a spray time calculated by the spray time calculation unit.

3. In Paragraph 1, A 3D upload unit that receives three-dimensional shape information regarding the object to be painted from the ordering company, and A 3D verification unit that verifies the validity of three-dimensional shape information uploaded to the above 3D upload unit, and A 3D download unit that downloads the three-dimensional shape information verified by the above 3D verification unit to a 3D powder coating automation system established at a coating company, and An estimate collection unit that receives painting cost estimate data from 3D powder coating automation systems of painting companies that have downloaded three-dimensional shape information, and A 3D powder coating automation system characterized by further including an quotation platform comprising a contractor selection unit that selects a contractor by analyzing quotation data collected in the quotation collection unit.

4. In Paragraph 1, The above-described spraying unit comprises a tube for transporting paint and a female part that is screw-fastened to a male part of a connector provided at the end of the tube, and a spray nozzle for spraying paint onto a target object. A 3D powder coating automation system characterized in that the female part of the spray nozzle and the male part of the connector are each provided with a threaded part having threads formed thereon and a non-threaded part not having threads formed thereon, and the female part is provided with a fastening rod having threads formed on its inner surface and capable of advancing toward the non-threaded part.

Images