JP3173303B2 - Paint film thickness distribution calculator - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coating film thickness distribution calculating device capable of easily grasping the coating film thickness distribution visually or numerically without actually performing a coating operation by a coating robot.

[0002]

2. Description of the Related Art Since the coating quality of a vehicle body greatly affects the durability of the vehicle and the like, it is required that the thickness of the coating on the coated surface be maintained at a predetermined value.
In the automatic painting by the painting robot of the vehicle body, if the painting condition is always kept constant, the film thickness changes depending on the shape of the surface to be painted. Changing. Conventionally, in order to make the coating thickness distribution on the painted surface constant, after performing rough teaching only with the motion trajectory of the painting robot by simulation, test painting (fine teaching) is performed many times by the actual painting robot, The painting conditions at each teaching position of the painting robot were determined by trial and error.

[0003] As a prior art document relating to a painting technique by a painting robot, off-line programming of a painting robot using a color graphics technique is known (author: Alexander Klein, author: Computer & Automation Institute of Technology, Hungarian Academy of Sciences). . According to this document, by obtaining the trajectory of the robot tip close to the optimum conditions, while reducing paint loss,
It is described that a good uniform painted surface is obtained.

[0004]

However, as in the prior art, when test coating is actually performed many times and the coating conditions at each teaching position of the coating robot are determined by trial and error, it takes a great deal of work to create an operation program for the coating robot. It takes a lot of man-hours. In addition, many paints and works are required for the test coating, and the material cost is also large.

[0005] In the case of off-line programming of a painting robot using the above-described color graphics technology,
The pattern shape of the paint to be applied is considered to be conical, and from the coating conditions (spray gun performance, paint usage, gun distance, gun feed speed) initially set assuming a geometric model, Since the film thickness value of the portion to be coated is calculated by simulation, only a theoretical film thickness value can be obtained. In an actual painting operation, the amount of paint applied changes due to a change in the shape of the surface to be painted, etc., so that the actual film thickness differs from the theoretical value, and there is a problem that the data does not conform to the painting site.

In the case of off-line programming of a painting robot using color graphics technology, the state of film thickness distribution is visualized by a change in color. For this purpose, the surface to be painted is divided into several grids. It is necessary to display a color proportional to the film thickness value in that unit. Therefore, it is necessary to have the data of the grid division, and there is also a problem that the data amount is greatly increased and the response of the data processing is reduced.

An object of the present invention is to provide a paint film thickness distribution calculating device capable of easily grasping a film thickness distribution close to an actual paint work by a paint robot without performing an actual paint work by a paint robot. With the goal.

[0008]

The coating film thickness distribution calculating device according to the present invention for achieving this object is as follows. (1) Storage means for storing the shape of the painting robot, workpieces to be painted, teaching work data, and film thickness distribution storage means for converting the coating film thickness distribution for a large number of coating conditions determined by a coating experiment into table data and storing the data. When the coating conditions to be simulated are set, the table data to be referred to corresponding to the set coating conditions is selected from the table data, and the coating film thickness distribution of the selected table data is displayed on the virtual surface in the front of the paint spraying direction. Display point generating means for generating display points in the form of the number of display points corresponding to the film thickness, and display point projecting means for projecting the display points on the virtual surface onto the surface to be coated of the workpiece. Paint thickness distribution calculator. (2) The above-mentioned (1), further comprising film thickness value calculating means for calculating a film thickness value at an arbitrary portion of the surface to be coated based on the density of the display points projected on the surface to be coated by the display point projecting means. Paint film thickness distribution calculator. (3) Film thickness distribution storage means for converting the coating film thickness distribution with respect to the coating conditions determined by the coating experiment into table data and storing the data, and storage means for setting a coating direction vector for each interpolation point based on the teaching position of the coating gun. A holding surface determining means for determining a holding surface for holding an arbitrary designated portion of the surface to be coated among the imaginary surfaces formed by the application direction vectors of the interpolation points, and interpolating from a relationship between the designated portion and the holding surface. The position of the coating gun between the points is determined, and a film thickness value at an arbitrary designated portion on the surface to be coated is calculated based on the position of the coating gun, the designated portion, and the coating film thickness distribution of the table data for the painting condition to be simulated. Film thickness value calculating means;
An apparatus for calculating a coating film thickness distribution, comprising:

[0009]

In the coating film thickness distribution calculating device of the above (1), the shape of the coating robot, the work to be coated, and the teaching work data necessary for the simulation stored in the storage means are read. When the coating conditions to be simulated are set in the display point generating means, the table data corresponding to the simulation coating conditions is selected from the table data stored in the film thickness distribution storage means. The display point generation means generates a coating film thickness distribution of the selected table data in the form of a number of display points corresponding to the film thickness on a virtual surface set forward in the paint spraying direction. Since the display point projecting means projects the display points on the virtual surface onto the surface to be coated,
It is possible to easily grasp the film thickness distribution from the scattered state of the display points on the surface to be coated. Since the film thickness distribution in the form of table data uses raw data actually obtained by a coating experiment, it is possible to grasp the film thickness distribution close to the actual coating operation by the coating robot. Therefore, there is no need to perform test painting with an actual painting robot many times and determine the painting conditions by trial and error, and the amount of work for creating an actual painting robot operation program (fine teaching) can be greatly reduced. Become. (2) In the coating film thickness distribution calculating device of the above (2),
Based on the point density of the display points projected on the surface to be coated by the display point projecting means, the film thickness value calculating means calculates the film thickness value at an arbitrary portion, so that the film thickness distribution can be grasped numerically easily. It becomes possible.

(3) In the coating film thickness distribution calculating device of (3), a coating direction vector is set in the storage means for each interpolation point based on the teaching position of the coating gun. When an arbitrary designated portion on the surface to be coated whose thickness value is to be known is designated, a clamping surface sandwiching the designated portion of the virtual surface formed by the application direction vector of the interpolation point is determined by the clamping surface determining means. You. Next, the position of the coating gun between the interpolation points is determined by the film thickness value calculating means from the relationship between the designated portion and the holding surface. When the position of the coating gun is calculated, the film thickness value calculating means determines the indicated portion by a coating experiment from the relationship between the position of the coating gun, the indicated portion, and the coating film thickness distribution in the table data for the coating conditions to be simulated. It is possible to grasp which portion of the coating film thickness distribution corresponds to this, and the film thickness value of the designated portion is calculated. The film thickness distribution in the form of table data stored in the film thickness value distribution storage means is raw data actually obtained by a coating experiment. Becomes possible.

[0011]

1 to 8 show a first embodiment of the present invention, and FIGS. 9 to 20 show a second embodiment of the present invention. Figure 4 shows CAD (Computer Aided Design)
1 shows a coating film thickness distribution calculation display device 1 built on a system, and has a configuration common to the first embodiment and the second embodiment. The coating film thickness distribution calculation display device 1 has a computer (CPU) 10. A hard disk 12, a display 15, and a keyboard 16 are connected to the computer 10. A display 20 is similarly connected to the computer 10 via a graphics controller 18. A hard copy 22 for printing out image contents is connected to the display 20. A mouse 23 is connected to the graphics controller 18.

First Embodiment As shown in FIG. 1, a computer 10 includes a display point generating means 24, a display point projecting means 26, and a film thickness value calculating means 2.
8 are formed. The display point generating means 24, the display point projecting means 26, and the film thickness value calculating means 28 are configured by programs stored in the computer 10. The hard disk 12 includes a storage unit 13 and a film thickness distribution storage unit 14. The storage means 13 stores the shape of the painting robot for simulation (algorithm determining the posture of the robot), the work to be painted (for example, design data of a vehicle bumper), the teaching work data (painting position, painting speed, painting pattern width, etc.). Is stored. The film thickness distribution storage means 14 stores table data for obtaining a coating film thickness distribution for many coating conditions by a coating experiment. In the film thickness measurement in the coating experiment, the film thickness after baking is measured. Table data from the film thickness distribution storage unit 14 is input to the display point generation unit 24.
To the display point generating means 24, for example, the coating conditions to be simulated via the keyboard 16 are input.

The coating conditions of the table data stored in the film thickness distribution storage means 14 include, for example, a paint discharge amount, a gun distance, an electrostatic coating voltage, and the like. The coating in the coating experiment is performed by one-shot coating (for example, 0.04 seconds = 1 interpolation). In other words, since the painting robot changes the trajectory every 0.04 seconds, it is necessary to change the painting conditions accordingly, so that the painting experiment is performed by one-shot painting. In the coating experiment, the coating film thickness is defined as table data at a radial distance of 2 nl (n = 0, 1, 2, 3,...) From the ejection center.

The display point generating means 24 is based on simulation coating conditions set via the keyboard 16.
Table data to be referred to is selected from the table data stored in the film thickness distribution storage means 14. The display point generating means 24 is, as shown in FIGS. 2 and 3, a virtual surface 50 set away from the tip of the paint gun 56 in the simulation by the same distance A as the gun distance in the paint experiment in the paint spraying direction. In addition, it has a function of causing the coating film thickness distribution of the selected table data to be disturbed in the form of the number of display points 52 corresponding to the film thickness. As shown in FIG. 2, the display point projecting means 26 is configured to simulate the ejection position of the paint T (the tip of the paint gun 56) and the virtual surface 50 on the simulation.
A function of calculating a vector 58 in a direction connecting each of the display points 52 generated above and projecting the display points 52 on the virtual surface 50 in the vector direction onto the surface 54 to be painted of the simulation work existing in the vector direction. Have. In this embodiment,
Although the virtual surface 50 is perpendicular to the axis of the coating gun 56, the virtual surface 50 may be inclined with respect to the axis of the coating gun 56. In this case, it is desirable that the surface to be coated in the coating experiment is also tilted by the same angle with respect to the axis of the coating gun that ejects the coating.However, in the case of a slight tilt, the film thickness value measured in a right angle state should be corrected. It is also possible to deal with.

The display 20 as a display means has a function of displaying the display points 52 projected on the surface 54 to be coated by the display point projection means 26 on a screen. The point projection means 26 is connected to a film thickness value calculation means 28. The film thickness value calculating unit 28 has a function of calculating a film thickness value at an arbitrary portion of the surface 54 to be coated based on the point density of the display points 52 projected on the surface 54 to be coated by the display point projecting unit 26. ing. The display 20 as a display unit also has a function of displaying the film thickness value calculated by the film thickness value calculation unit 28 on a screen.

Next, the operation of the coating film thickness distribution calculating device according to the first embodiment will be described. FIG.
4 shows a processing procedure of a film thickness display simulation in the coating film thickness distribution calculating device 1. In step 100 of FIG. 5, necessary data is read into a work area in the RAM of the computer 10. The necessary data is the shape of the painting robot, the work to be painted, and the teaching work data already stored in the storage means 13 of the hard disk 12. When the processing of step 100 is completed,
Proceeding to step 110, the coating conditions for the simulation are set by the keyboard 16 to the display point generating means 24 in FIG.
Is input to

When the simulation painting conditions are set, the process proceeds to step 120, where a painting robot operation simulation on the screen of the display 20 is started, and painting work on the screen by the painting robot is performed. The trajectory generation of the painting robot is the one interpolation (0.04 seconds) described above.
This is performed every time, and a continuous coating simulation can be performed by making this continuous, so that the film thickness distribution on the screen can be grasped. When the generation of the trajectory of the painting robot in one interpolation is completed, the process proceeds to step 130, and the film thickness display processing on the screen at this position is performed.

FIG. 6 shows the film thickness display processing in step 130. In step 130-1 of FIG. 6, table point data to be referred to in the hard disk 12 is selected by the display point generating means 24 based on the simulation painting conditions input from the keyboard 16.
Next, proceeding to step 130-2, reading of the film thickness value at a radius of 2nl (n = 0, 1, 2,...) From the center of the virtual surface 50 is performed based on the film thickness distribution of the selected table data. When the process of step 130-2 ends, the process proceeds to step 130-8, and it is determined whether or not the generation of the display point 52 proportional to the film thickness value has ended. here,
If the generation of the display point 52 has been completed, the process proceeds to the next process, and the process in step 140 of FIG. 5 is performed.

At step 130-8, the display point 52
If it is determined that the occurrence of has not ended, the process proceeds to step 130-3, where the radius r and the angle θ
And a display point 52 proportional to the film thickness value is generated. The range of the radius r is (2n-1) l to (2n + 1) l
It is. Here, n = 1, 2, 3,..., And when n = 0, the range of the radius r is 0 to 1. When n = 1, the range of the radius r is l to 3l, and when n = 2, the range of the radius r is 3l to 5
l. The range of the angle θ is 0 to 360 °.
In this embodiment, as shown in FIG.
In the case of μ, the number of display points proportional to 20 is generated, and in the case of the film thickness of 15 μ, the number of display points proportional to 15 is generated.

The reason that the number of display points 52 proportional to the film thickness value is disturbed on the virtual plane 50 in step 130-3 is to scatter the display points 52 uniformly. Further, in this embodiment, when n = 1, the thickness of the table data at the radius r = 2l is 15 μ, so that a number of points proportional to 15 are generated, but the display range area (l to 3l) ) Is eight times as large as n = 0, so that 15a × 8 = 120a (a is a proportional constant) display points 52 are actually displayed.

When the processing of step 130-3 is completed,
Proceeding to step 130-4, the display point projection means 26 calculates a vector 58 in the direction connecting the tip of the paint gun 56 and the display point 52 on the virtual surface 50. Next, proceeding to step 130-5, the display point 52 on the virtual surface 50 is
The image is projected onto the surface to be painted 54 existing in the vector direction by the display point projecting means 26. When the display point 52 on the virtual surface 50 is projected on the surface 54 to be coated, the process proceeds to Step 130-6, and it is determined whether or not the projection distance is within L mm from the tip of the coating gun 56.

The determination in step 130-6 is that if the projection distance is set to infinity, the paint does not adhere to the surface 54 to be painted, even though the paint does not reach the surface. It is because it will be. The standard value of the projection distance L is obtained in advance by an experiment. In step 130-6, the projection distance is Lm
m, it is determined in step 130-4
And the above processing is repeated for another display point.

If it is determined in step 130-6 that the projection distance is within Lmm, step 130
Proceeding to -7, the display of the display point 52 on the surface 54 to be coated by the display 20 is performed. FIG. 8 shows the surface to be coated (vehicle bumper) 5 displayed on the screen of the display 20.
4 shows an example of the coating film thickness distribution in FIG. As shown in FIG. 8, by displaying the film thickness distribution of the coating surface 54 by projecting the display points 52 onto the coating surface 54, the film thickness distribution can be easily grasped visually. In other words, the portion where the density of the display points 52 projected on the surface to be coated 54 is high has a large film thickness, and the portion where the density of the display points 52 is low has a small film thickness. It is possible to grasp by.

If it is determined in step 130-8 that the generation of the point proportional to the film thickness value has been completed, the process proceeds to step 140 in FIG. 5, and it is determined whether or not all the robot operation simulations have been completed. Is done. If it is determined that the robot operation simulation has not been completed, the process returns to step 120, and the film thickness display processing in the next one interpolation is continued.

In the next one interpolation shown in FIG. 2, the number of display points based on the film thickness value of the table data is generated on the virtual surface and projected on the surface to be coated, so that the display points overlap each other. You can simulate the situation of painting with a painting robot on the screen. When the projection display of the display points 52 on the surface 54 to be coated based on the robot operation program is completed as described above, the process proceeds to step 150, and the film thickness display simulation processing is ended.

As shown in FIG.
By displaying the projection on the surface 54 to be coated, the film thickness distribution can be easily grasped visually from the scattered state, and the simulation coating conditions can be easily corrected. Further, since the raw data of the film thickness distribution actually obtained by the coating experiment is used, it is possible to display the film thickness distribution close to the actual coating operation by the coating robot. Therefore, the precise teaching (operation program creation) of the actual coating robot based on the teaching data of the coating film thickness distribution calculating device 1 becomes easy, and the number of steps required for the fine teaching can be greatly reduced.

FIG. 7 shows a film thickness value calculation process. The process of FIG. 7 calculates the film thickness value of an arbitrary portion on the surface 54 to be coated based on the point density of the display points 52 projected on the surface 54 to be coated displayed by the film thickness display process of FIG. Things. In step 200 of FIG. 7, by operating the mouse 23, the intersection (54a) on the surface 54 to be painted specified by the cursor displayed on the screen of the display 20 is calculated. Next, the process proceeds to step 230, where it is determined whether the processing has been completed by the number of display points 52 projected on the surface 54 to be coated. Here, display point 5
If it is determined that the processing for the number of 2 has not been completed, the process proceeds to step 210.

In step 210, it is sequentially determined whether or not the projected display point 52 exists within a circle having a radius S with the intersection as the center. If it is determined in step 210 that the projected display points 52 are present within a circle having a radius S centered on the intersection, the process proceeds to step 220, and the number of projected display points 52 is accumulated. After making a determination at 230 for all projected display points 52,
Proceed to step 250. In step 250, the cumulative number of the projected display points 52 is displayed on the screen of the display 20 as the film thickness value.

As described above, by moving the cursor on the screen of the display 20 with the mouse 23, it is possible to display the film thickness value of an arbitrary portion of the surface 54 to be coated. Can be easily grasped. Therefore, it is easy to determine how much the correction amount of the film thickness value should be set, and the amount of work for creating the operation program of the painting robot can be reduced.

Second Embodiment As shown in FIG. 10, the computer 10 is provided with a holding surface determining means 63 and a film thickness calculating means 64.
The holding surface determining means 63 and the film thickness value calculating means 64 are constituted by programs stored in the computer 10. The storage means 61 and the film thickness distribution storage means 62 are formed on the hard disk 12. The storage means 61 stores, for example, the shape of the painting robot for simulation (algorithm for determining the posture of the robot), the work to be painted, and teaching work data (data such as painting position, painting speed, painting pattern width). I have. Also, the storage means 6
As shown in FIG. 9, for example, as shown in FIG. 9, for each interpolation point based on the teaching position of the coating gun 70, the tip position of the coating gun 70 and the coating direction vector (O: orientation, A: approach) are set (stored) as data. Is done.

The coating thickness distribution storage means 62 stores the coating thickness distribution with respect to the coating conditions obtained by the coating experiment in the form of table data. In the film thickness measurement in the coating experiment, the film thickness after baking is measured. In the coating experiment, a test piece 66 shown in FIG. 12 was used. In the coating experiment of the present embodiment, unlike the one-shot coating of the first embodiment, continuous coating was performed in the direction of the arrow, and the film thickness value at a certain cross section was measured at regular intervals (for example, 10 mm). The thickness distribution data was set as μ. In this case, table data for many coating conditions can be obtained by performing experiments by increasing the gun distance (the distance from the tip of the coating gun to the surface to be coated), the gun speed (coating speed), the amount of paint discharged, and the like. Thus, it is expected that the accuracy of calculating the film thickness value is improved.

The holding surface determination means 63 is a simulation
Arbitrary value for determining the film thickness value on the surface 71 to be coated
Pointed site X₀Is specified with the cursor (for operation of the mouse 23).
), The interpolation point Q₁, Q_TwoApplication direction vector
O, A (O₁, A₁And O_Two, A_TwoMade by the instructions
Site X₀Virtual holding surface (infinite virtual surface) 72, 7
3 is provided. The film thickness value calculating means 64 includes:
Simulation via the keyboard 16 as input means
You can enter the coating conditions. Thickness value calculation means
64 is the designated part X₀And the relationship between the clamping surfaces 72 and 73
Interpolation point Q₁, Q _TwoOf the tip P of the paint gun 70₀Seeking
The tip position P of the paint gun 70₀And indicated site X₀And stains
Film thickness distribution data μ
From the indicated location X₀Is the coating thickness from the coating experiment
Know which part of the distribution it corresponds to, and₀
Has the function of calculating the film thickness value in Display means
The display 20 is operated by the film thickness value calculating means 64.
It has a function of displaying the calculated film thickness value.

Next, the operation of the coating film thickness distribution calculating device according to the second embodiment will be described. FIG.
Shows the processing procedure of the robot operation simulation in the coating film thickness distribution calculating device 1. The robot operation simulation in FIG. 13 is performed by a program that has been previously taught on a CAD system (robot simulation application). Step 30 in FIG.
At 0, necessary data is read into a work area in the RAM of the computer 10. The necessary data is the shape of the painting robot, the work to be painted, and the teaching work data already stored in the storage means 61 of the hard disk 12. When the process of step 300 is completed, the process proceeds to step 310, where the coating conditions for simulation are input to the computer 10 by the keyboard 16.

After the simulation painting conditions are set, the process proceeds to step 320, where a painting robot operation simulation on the screen of the display 20 is started, and painting work on the screen by the painting robot is performed. The trajectory of the painting robot is generated for each one of the above-mentioned interpolations (for example, 0.05 seconds in the present embodiment), and a continuous painting simulation can be performed by making this continuous. Here, the interpolation points are different from the teaching positions, and usually a large number of interpolation points exist between the teaching positions.

At the interpolation point, as shown in step 330, the tip position of the coating gun 70 and the coating direction vector (O: orientation, A: approach) are stored. In step 340, it is determined whether or not the robot operation simulation has been completed. If not completed, the process returns to step 320;
The process proceeds to 0, and the robot operation simulation processing ends. After the processing in FIG. 13, the film thickness value calculating means 6 in FIG.
In the case where only the calculation of the film thickness value according to No. 4 is executed, that is,
If it is not necessary to check the robot operation, it is not necessary to simulate the robot operation on the screen, and only the trajectory may be generated internally (Dry Ru).
n).

FIG. 14 shows the film thickness value calculation processing.
This film thickness value calculation processing can be performed by preparing the film thickness distribution data μ by the coating experiment in FIG. 12 and the data by the robot operation simulation processing in FIG.
In step 400 of FIG. 14, the indication portion X ₀ is where you want to calculate a film thickness value on the coated surface 71 of FIG. 9 and instructs at cursor, the position of intersection of the screen on the vertical direction of the display 20 (x _0, y _0, z ₀₎ is required. Next, look its on when they were painted for the indicated sites x _0, i.e. whether at any locus of painting robot (the position of any painting gun) the film thickness is formed. For this, first, the process of step 410 is performed.

[0037] At step 410, it calculates the two surfaces sandwiching the instruction site X _0. In Figure 9, and an infinite virtual plane 72, 73 at the interpolation point Q ₁ and the interpolation point Q ₂ is present in the positional relationship sandwiching an instruction site X _0. Narrow the ever what between interpolation point during the operation was painted an indication site X _0. FIG.
Shows a process of calculating an infinite virtual plane 72 and 73 sandwiching the instruction site X _0. In step 410-1 in FIG. 15, the surface formed by the two vectors (O, A) is sequentially calculated for each interpolation point using the tip position and the coating direction vector of the coating gun 70 in FIG. It is extracted those present this to the instruction site X ₀ a sandwich positional relationship as an infinite virtual plane.

Here, there is a case where the same portion of the surface 71 to be coated is repeatedly coated due to teaching,
Infinite virtual surface sandwiching the instruction portion X ₀ is likely to be present two sets or more. As a method to continue to extract an infinite virtual plane, in step 410-2, will by substituting the coordinate value of the command part X ₀ which directs the expression of Figure 16 and the following equation, is the result value in step 410-3 We look for two faces that are "positive → negative" or "negative → positive". The calculated value t
Is intended to indicate the direction of the perpendicular foot dropping off from the coordinate value of the command part X ₀ of FIG. 16, which of the positive and negative changes in two infinite virtual plane 72 and 73 sandwiching the instruction region X ₀ positional relationship Means that

[0039]

(Equation 1)

If it is determined in step 410-3 that the value of t is opposite to that of the immediately preceding one, the process proceeds to step 410-4. processing the X ₀ as two surfaces sandwiching, the process proceeds to step 420 following processing. If it is determined in step 410-3 that the value of t is not reversed from the previous value, the process proceeds to step 410-6. here,
From the relationship between W and dd to be described later, it is determined whether or not the entire range in which the film thickness is formed is sandwiched between the two infinite virtual surfaces 72 and 73. In step 410-6, W> dd
When it is determined that W> dd, the process returns to step 410-1. When it is determined that W> dd is not satisfied, step 41-1 is performed.
The process proceeds to 0-7, and although not sandwiched between the infinite virtual surfaces 72 and 73, there is a possibility that a film is formed.

FIGS. 19 and 20 show two infinite virtual planes 72 and 73 as viewed from above. As shown in FIG. 19, W (the intersection of the line of intersection and O ₁ dihedral, the distance to the film thickness distribution center in the film thickness distribution data mu) and dd (thickness of the film thickness distribution data mu 9 When the relationship (the maximum pattern from the distribution center) is W> dd, the range in which the film thickness is formed can be calculated because it is sandwiched between the two infinite virtual planes 72 and 73, as shown in FIG. In the case where W <dd, part of the range in which the film thickness is formed is two infinite virtual surfaces 72,
There is a phenomenon that the calculation is not performed correctly because the frame is not sandwiched by 73. In other words, as shown in FIG. 20, although the film thickness should have actually been formed by moving the film thickness distribution data μ, it is not sandwiched between the two infinite virtual surfaces 72 and 73. Is not changed. Therefore, in this case, it is necessary to calculate the film thickness value by performing the same processing as in the case where it is sandwiched between the two infinite virtual surfaces 72 and 73.

When a certain infinite virtual plane is parallel to the next infinite virtual plane (ψ = 0), both normal vectors are in the same direction, and unless there is a designated portion X ₀ between the two infinite virtual planes. t
The value of is not reversed from the previous one. However,
As a case where the film thickness is formed even if the value of t is not reversed from the previous value, there is a case where a certain infinite virtual surface and the next infinite virtual surface are rotated by 90 degrees or more. Consider such a case. According to FIGS. 19 and 20, w = v × i
The relationship of / tan (ψ) holds. Here, v: target point speed in FIG. 9, i: interpolation interval, ψ: angle formed by O ₁ and O ₂ . In this case, if the range of the angle ψ is -π / 2
Assuming that <ψ <π / 2 (ψ ≠ 0), the angular velocity ω = ψ / i at the target point of the painting robot is obtained. Here, i = 0.0
Substituting 5 seconds (interpolation interval for a general spray painting robot), ω ≒ 10π is required to rotate ψ to around π / 2. Since it is impossible to give an actual robot an angular velocity of 10π rag / sec, the range of ψ is −π / 2 <ψ <π /
It can be seen that it may be set as 2 (設定 0). That is, a certain infinite virtual plane and the next infinite virtual plane do not rotate by more than 90 degrees. For this reason, when rotating 90 degrees or more, it may be ignored.

Pointed site X₀Two infinite virtual surfaces 7 sandwiching
When 2, 73 are calculated, the paint gas is
The detailed position of the button 70 is determined. Tip position of coating gun 70
P₀Is the designated site X₀And two infinite virtual planes sandwiching it 7
The calculation process is performed based on the positional relations 2 and 73.
Shown in In step 420-1 of FIG.
Interpolation point Q₁, Q_TwoIndicates a line 76 parallel to the line 75 connecting
Rank X₀Generated so that it passes over the parallel line 76 and infinity
Intersection X with virtual surfaces 72 and 73₁, X_TwoTo step 420
Determined by -2. Next, this intersection X₁, X_TwoAnd indication site
X₀The ratio (m, n) based on the positional relationship of
-3, and the interpolation point Q is calculated using this ratio. ₁, Q_TwoAmong
By dividing the line 75, the tip position P of the coating gun 70
₀Ask for. Tip position P₀Is required, step 4
Proceed to 20-5 and proceed to the next process (step 430).

[0044] At step 430, various values necessary for calculating the film thickness value at the indicated sites X ₀ is calculated. FIG.
Shows a processing procedure for calculating various values. In step 430-1 of FIG. 18, the direction vector D and the distance h between them are calculated by connecting the tip position P ₀ of the coating gun 70 and the designated portion X ₀ . Further, in step 430-2, approach vector A ₀ interpolation points Q _1, closer to Q ₂ (interpolation point in FIG. 9 Q at the tip position P _0
In step 430-3, the angle θ formed by the approach vector A ₀ and the direction vector D is calculated. In step 430-4 calculates the speed by the movement time T ₀ between interpolation points Q _1, Q ₂ of the distance and the robot spray gun between the intersection point X _1, X ₂ of the infinite virtual plane, aiming it Obtained as the point velocity V. When the target point speed V is calculated, the process proceeds to step 430-5, and proceeds to the next process.

When the direction vector D, the distance h, the angle θ, and the target point velocity V are calculated in step 430 of FIG. 14, the process proceeds to step 440. In step 440, FIG.
The pattern distance d from the center of the film thickness distribution data μ is calculated from the gun distance g and the angle θ in the coating experiment shown in FIG. The pattern distance d is d = g · tan
θ. In step 450, as shown in FIG. 11, the film thickness value μ ₀ at the pattern distance d is referred to from the film thickness distribution data μ stored as table data in the film thickness distribution storage means 62.

The film thickness distribution data μ to be referred to is
Simulation coating conditions.
When there is no film thickness distribution data μ identical to the coating conditions
Is the film thickness distribution data closest to the simulation coating conditions.
Is referred to. As shown in FIG.₀Is
It is a value equivalent to the pattern distance d in the coating experiment.
And the film thickness μ₀Is the designated part X₀Corrected to film thickness value at
It is. This correction consists of two steps: gun distance correction and gun speed.
Step on the steps. In step 460, the film thickness value μ ₀The gun
The distance is corrected and the corrected film thickness value μ₁Is μ₁= Μ
₀× g / hcosθ.

Film thickness μ₀When the gun distance correction is performed,
Proceeding to step 470, the film thickness value μ₁Based on gun
Speed correction is performed. Target point speed V is applied during coating experiment
If it is different from the moving speed of the gun,₀In
The film thickness is μ₁The film thickness μ
₁Is corrected. Film thickness μ by gun speed correction_TwoIs μ _Two
= Μ₁× (r / T₀) / V. Where r is
Interpolation point Q₁, Q_TwoIndicates the distance between them. In addition, in the painting experiment
Gun distance g and paint gun during simulation
Tip position P₀And the distance from the
The moving speed and simulation of the coating gun in the coating experiment.
If the target point speed V at the time of the
Uncorrected film thickness μ₀Is the designated part X as it is₀Film thickness and
Become.

After the film thickness value μ ₂ has been calculated by the gun speed correction, the process proceeds to step 480, where it is determined whether or not a check has been made on the surface sandwiching the designated portion X ₀ at all interpolation points.
If the check has not been completed for all interpolation points, the process returns to step 410 and the above-described processing is repeated. Step 4
If the check at all interpolation point 80 is determined to be ended, the process proceeds to step 490 to calculate a film thickness value mu ₂ among all subjects interpolation points, to accumulate. The process to do the step 490, an instruction portion X ₀ is two infinite virtual plane 7
2,73 not limited to only being sandwiched, when the instruction portion X ₀ by the relationship of the teaching are painted from a different direction, infinite virtual surface sandwiching the instruction portion X ₀ is made larger than this, the results This is because the film thickness value is accumulated. The total film thickness Δμ ₂ calculated in step 490 is displayed as the final film thickness value on the screen of the display 20 in step 500. Therefore, it geometrically simulation calculating the film thickness value at the indicated site X _0.

In the case of the first embodiment, all coating operations are simulated, display points corresponding to the film thickness values are generated at all interpolation points, and the film thickness value is obtained from the point density of the display points. To change the conditions and obtain the film thickness value,
It is necessary to simulate all the painting operations and generate new display points again, which takes much time. In contrast, even in the second embodiment changes the coating conditions, since the coating direction vector after simulated once every painting operations at each interpolation point has already been grasped, the spray gun to the indicated site X _o It is possible to specify 70, and it is not necessary to simulate all the painting operations again. Therefore, if you want to find a film thickness value by changing the coating conditions, will be only may newly be captured thickness distribution data corresponding to the coating conditions input from the keyboard 16, the film in an arbitrary instruction site X _o The thickness value can be obtained in a short time.

[0050]

According to the present invention, the following effects can be obtained. (1) In the coating film thickness distribution calculating device of the first aspect, based on the coating conditions for the simulation to be set,
The display point generating means selects table data of the film thickness value distribution stored in the film thickness distribution storage means, and paints the coating film thickness distribution of the selected table data on this virtual surface in the paint spraying direction front. Generated in the form of a corresponding number of display points,
Since the display points generated on the virtual surface are projected on the surface to be coated by the display point projecting means, the thickness distribution can be easily grasped from the scattered state of the display points on the surface to be coated.
Further, since the raw data of the film thickness distribution obtained by the coating experiment is used, it is possible to display the film thickness distribution close to the coating operation by the actual coating robot. Therefore, in the actual teaching by the coating robot, the teaching data by the coating film thickness distribution calculating device can be effectively used, and the man-hour required for the teaching (operation program creation) of the coating robot can be greatly reduced. Further, by reducing the work amount of the fine teaching, the amount of paint, thinner, and the like used in the fine teaching can be reduced as compared with the related art, and the dangerous work due to the handling of the painting robot is also reduced. (2) In the coating film thickness distribution calculating device according to the second aspect, the film thickness value at an arbitrary portion of the surface to be coated is determined based on the point density of the display points projected on the surface to be coated by the display point projecting means. Since the value is calculated by the value calculating means, the film thickness value at an arbitrary portion can be easily grasped numerically. Therefore, the correction amount of the film thickness value can be quickly determined, and the work efficiency of the simulation can be improved. (3) In the coating film thickness distribution calculating device according to the third aspect, a coating direction vector is set for each interpolation point based on the teaching position of the coating gun, and among the imaginary surfaces formed by the coating direction vector, the coated surface The holding surface for holding an arbitrary designated portion in the above is determined by the holding surface determining means, and the film thickness value calculating means determines the position of the coating gun between the interpolation points from the relationship between the designated portion and the holding surface, and determines the position of the coating gun. Since the film thickness value at an arbitrary designated portion of the surface to be coated is calculated based on the position, the designated portion, and the coating film thickness distribution of the table data with respect to the painting condition to be simulated, the coating condition is changed and the designated designated portion is changed. Even when obtaining the film thickness value, it is not necessary to simulate all the painting operations, and the work efficiency of correcting the film thickness value can be further improved.

[Brief description of the drawings]

FIG. 1 is a control block diagram of a coating film thickness distribution calculating device according to a first embodiment of the present invention.

FIG. 2 is a schematic diagram showing a state of a simulation at the time of one-shot painting in the apparatus of FIG. 1;

FIG. 3 is a schematic diagram showing a film thickness distribution on a virtual plane in FIG. 2;

FIG. 4 is a schematic configuration diagram of the apparatus of FIG. 1;

FIG. 5 is a flowchart showing an overall processing procedure of a film thickness display simulation in the apparatus of FIG. 1;

FIG. 6 is a flowchart showing a control process in the film thickness display of FIG.

FIG. 7 is a flowchart showing a control process in a film thickness value calculating means of the apparatus of FIG.

FIG. 8 is an image showing a film thickness distribution of a vehicle body displayed on the display means of FIG. 1;

FIG. 9 is a conceptual diagram of a film thickness value calculation by a coating film thickness distribution calculating device according to a second embodiment of the present invention.

FIG. 10 is a control block diagram of a coating film thickness distribution calculating device according to a second embodiment of the present invention.

FIG. 11 is a schematic diagram showing a relationship among a coating gun, an indicated portion, and a film thickness distribution in FIG. 9;

FIG. 12 is a perspective view showing a coating experiment method for obtaining the film thickness distribution data of FIG.

FIG. 13 is a flowchart showing a procedure of a robot operation simulation process by the apparatus of FIG. 10;

14 is a flowchart showing a procedure of a film thickness calculation process by the apparatus of FIG.

FIG. 15 is a flowchart showing a control process in step 410 of FIG.

FIG. 16 is a schematic diagram for explaining a procedure for obtaining an infinite virtual plane sandwiching a designated portion in the control processing of FIG. 15;

FIG. 17 is a flowchart showing a control process in step 420 of FIG.

FIG. 18 is a flowchart showing a control process in step 430 of FIG.

FIG. 19 is a schematic diagram showing a state in which the range in which the film thickness is formed in FIG. 9 is entirely sandwiched by two infinite virtual planes.

20 is a schematic diagram showing a state in which a part of the range in which the film thickness is formed in FIG. 9 is not sandwiched by two infinite virtual planes.

[Explanation of symbols]

REFERENCE SIGNS LIST 1 coating film thickness distribution calculation display device 10 computer 13 storage means 14 film thickness distribution storage means 24 display point generating means 26 point projection means 28 film thickness value calculation means 50 virtual plane 52 display point 54 coated surface 61 storage means 62 film thickness distribution storage unit 63 sandwiching surface determining means 64 thickness value calculating means 70 spray gun 71 to be coated surface 72 clamping surface 73 clamping surface μ thickness distribution data Q ₁ interpolation point Q ₂ interpolation point X ₀ instruction site

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B05B 12/00 B05C 11/10 B05D 1/02

Claims (3)

(57) [Claims] 1. A storage means for storing data of a shape of a painting robot, a workpiece to be painted, and teaching work data, and a film thickness distribution for converting a paint film thickness distribution for a large number of paint conditions obtained by a paint experiment into table data and storing the data. When the coating condition to be simulated is set, table data to be referred to corresponding to the set coating condition is selected from the table data, and the coating film thickness of the selected table data is stored in a virtual plane ahead in the paint spraying direction. Display point generating means for generating a distribution in the form of a number of display points corresponding to the film thickness, and display point projecting means for projecting the display points on the virtual surface onto the surface to be coated of the workpiece. Characteristic paint film thickness distribution calculator. 2. A film thickness calculating means for calculating a film thickness value at an arbitrary portion of a surface to be coated based on a point density of a display point projected on the surface to be coated by the display point projecting means. An apparatus for calculating a coating thickness distribution described in the above. 3. A film thickness distribution storage means for converting the coating film thickness distribution with respect to the coating conditions obtained by a coating experiment into table data and storing the table data, and a storage for setting a coating direction vector for each interpolation point based on the teaching position of the coating gun. Means, a holding surface determining means for determining a holding surface for holding an arbitrary designated portion of the surface to be coated among virtual surfaces formed by the application direction vectors of the interpolation points, and a relationship between the designated portion and the holding surface. The position of the coating gun between the interpolation points is obtained from the position of the coating gun, the designated portion and the coating thickness distribution of the table data with respect to the coating condition to be simulated, and the film thickness value at an arbitrary designated portion of the surface to be coated is determined. And a film thickness value calculating means for calculating.