JP6137034B2 - Vehicle sealer coating apparatus and teaching method therefor - Google Patents

Description

  The present invention relates to a vehicle sealer application device that applies a sealer to an overlapping portion of a vehicle door by hemming, for example, and a teaching method therefor.

  In general, the outer edge of the door for a vehicle is formed by overlapping the outer edge of the outer panel and the outer edge of the inner panel, and the outer peripheral flange end standing on the outer edge of the outer panel is sandwiched between the outer edge of the inner panel and the back side of the outer panel. Hemming is performed by folding back and closing. As shown in FIG. 8, a sealer coating device 100 in which a sealer gun 101 having a sealer nozzle 103 formed at the tip thereof is attached to the tip of an arm of the coating robot 102 is provided, and the vehicle door (work W) is hemmed and superimposed. In order to improve waterproofness and rustproofness etc., the sealer is automatically applied to the part. Therefore, it is necessary to correctly teach (teaching) the coating robot 102 so that the position of the sealer nozzle 103 that discharges the sealer corresponds to the overlapped portion of the workpiece W that has been hemmed.

In relation to teaching of this coating robot, for example, Patent Document 1 discloses a teaching device for a painting robot that facilitates an operation of adjusting the distance between the coating nozzle and the surface to be coated to a predetermined distance. Yes.
In the teaching device 200, as shown in FIG. 9, the coating application straight path L0 from the coating nozzle 201 to the surface to be coated 202 is positioned at a right angle to the surface to be coated 202, and generates slit lights L11 and L21. The two light source devices 203 and 204 are mounted on the coating nozzle 201 optically symmetrically with respect to the paint application straight path L0, and the optical directions of both the light source devices 203 and 204 are configured with a predetermined angle θ. Further, the slit lights L11 and L21 from both the light source devices 203 and 204 cross in a cross shape on the surface 202 to be coated. Further, the television camera 205 is arranged on the paint application straight line L0, and the signal from the television camera 205 is received by the reception circuit 206 and displayed on the monitor television 207.
According to the teaching device 200, the light source devices 203 and 204 are mounted while the slit light L11 and L21 are imaged by the television camera 205 and confirmed by the monitor television 207 that the crossed surface 202 is crossed on the surface 202 to be coated. The coating nozzle 201 can be adjusted to a predetermined position.

Japanese Utility Model Publication No. 4-18789

However, the teaching device 200 of Patent Document 1 can confirm on the monitor television 207 that the slit lights L11 and L21 cross in a cross shape on the surface 202 to be coated, but the coating nozzle 201 and the object to be coated at that time can be confirmed. The distance from the surface 202 cannot be calculated.
Therefore, as shown in FIG. 10, when applying the sealer to the hemming overlapped portion W3 at a position where it is difficult to arrange the light source devices 203 and 204 and the TV camera 205 (see FIG. 9), the coating robot 102 is used. There was a problem that teaching was not possible with high accuracy.
Further, since the teaching device 200 of Patent Document 1 cannot quantitatively record the positional relationship between the coating nozzle 201 and the surface 202 to be coated, the application result is confirmed from the beginning when the teaching correction is made for the shape change of the surface 202 to be coated. Thus, there is a problem that a troublesome teaching operation such as correcting a defective portion is required.

  The present invention has been made to solve the above-described problems, and provides a vehicle sealer coating apparatus and a teaching method thereof capable of teaching a coating robot with high accuracy by quantitatively calculating the position of a sealer nozzle with respect to a workpiece. For the purpose.

In order to solve the above problems, a vehicle sealer coating apparatus and a teaching method thereof according to the present invention have the following configurations.
(1) A sealer gun having a sealer nozzle with a discharge port formed at the tip, a light source device that generates a light beam irradiated on the workpiece, and an imaging camera that captures a light beam image irradiated on the workpiece by the light source device And a coating robot capable of mounting the sealer gun, the light source device, and the imaging camera, and a vehicle sealer coating apparatus that applies a sealer from the discharge port to a hemming overlapping portion formed on a workpiece. And
The imaging camera captures an image from a direction perpendicular to a workpiece surface, and the light source device irradiates the light beam on the workpiece from an inclination direction with respect to an imaging direction of the imaging camera;
The discharge port is formed such that the discharge direction of the sealer is the same or opposite to the imaging direction,
An arithmetic unit that calculates a vertical distance of the ejection port with respect to the overlapping portion based on a movement amount that moves in a direction parallel to the work surface from a reference position of the light image captured by the imaging camera; It is characterized by providing. Here, the light source device is not particularly limited as long as it is a light source capable of irradiating a light beam, but a laser light irradiation device having excellent light straightness is preferable. The light beam may be visible light or non-visible light as long as it can be captured by the imaging camera. The light beam may be a spot light beam or a slit light beam.

In the present invention, the imaging camera captures an image from a direction perpendicular to the workpiece surface, and the light source device irradiates the workpiece with a light beam from an inclination direction with respect to the imaging direction of the imaging camera. When the imaging camera is moved in the direction perpendicular to the work surface, the position of the light image captured in proportion to the amount of movement of the imaging camera moves in a direction parallel to the work surface.
In addition, since the discharge port of the sealer is formed in the same direction as the imaging direction, the amount of movement of the imaging camera that moves in the direction perpendicular to the workpiece surface is the amount of discharge to the overlapping part that applies the sealer. This corresponds to the amount of movement of the exit in the vertical direction.
In addition, since it includes an arithmetic unit that calculates the distance in the vertical direction of the discharge port with respect to the overlapping portion based on the amount of movement that moves in the direction parallel to the work surface from the reference position of the light image captured by the imaging camera, The coating robot can be taught so that the distance calculated by the arithmetic unit matches the optimum value (predetermined value) for sealer coating. Note that the optimum value (predetermined value) for sealer application is set based on the test result obtained by performing a sealer application test before teaching.
Therefore, according to the present invention, it is possible to provide a vehicle sealer coating apparatus that can quantitatively calculate the position of the sealer nozzle relative to the workpiece and teach the coating robot with high accuracy.

In addition, if teaching is performed with the sealer gun removed from the coating robot, this sealer coating device will not cause interference of the sealer nozzle with the workpiece and enables quick teaching. However, the sealer gun is not necessarily removed from the coating robot. There is no need.
In addition, the sealer coating device is provided with a display device that displays the distance calculated by the arithmetic unit (for example, the gap between the discharge port and the overlapping portion), and the distance is manually applied while the operator confirms the distance. Although the position of the robot may be corrected, the application robot may automatically correct the position so that the distance calculated by the arithmetic unit becomes the optimum value (predetermined value) for the sealer application without providing the display device.

(2) In the vehicle sealer coating apparatus described in (1),
The light source device generates two slit light beams that irradiate the workpiece with an inclination angle, and both slit light beams intersect within the imaging range of the imaging camera.

In the present invention, the light source device generates two slit light beams that irradiate the workpiece with an inclination angle, and both the slit light beams intersect within the imaging range of the imaging camera. The distance in the vertical direction of the discharge port with respect to the overlapping portion can be calculated on the basis of the amount of movement of the slit ray image captured in the direction from the reference position of the crossing position in the direction parallel to the work surface. In this case, the arithmetic device can specify the light beam image captured by the imaging camera as a point image at the crossing position of the slit light beam image, and therefore calculates the distance in the vertical direction of the discharge port with respect to the overlapping portion with higher accuracy. can do.
In addition, the crossing position in the slit ray image captured by the imaging camera is separated in the opposite direction with respect to the reference position depending on whether the vertical distance of the discharge port relative to the overlapped portion is longer or shorter than the predetermined value. To do. Therefore, it is possible to quickly teach the coating robot by determining which crossing position of the slit light beam image captured by the imaging camera is away from the reference position.
Therefore, according to the present invention, it is possible to provide a vehicle sealer coating apparatus capable of quantitatively calculating the position of the sealer nozzle with respect to the workpiece and teaching the coating robot more accurately and quickly.

  Even in this case, the sealer coating apparatus is provided with a display device that displays the distance calculated by the arithmetic unit (for example, the gap between the discharge port and the overlapping portion), and the operator confirms the distance. While the position of the coating robot may be corrected manually, the coating robot automatically corrects the position so that the distance calculated by the calculation device is the optimum value (predetermined value) for sealer coating without providing the display device. You may do it.

(3) In the vehicle sealer coating apparatus described in (2),
The arithmetic unit calculates a discharge angle of the discharge port with respect to the overlapping portion based on a crossing angle in a slit light beam image captured by the imaging camera.

  In the present invention, the computing device calculates the discharge angle of the discharge port with respect to the overlapping portion based on the crossing angle in the slit light beam image captured by the imaging camera. The coating robot can be taught with higher accuracy while being held in place. As a result, it is possible to prevent, for example, a sealer application failure such that the sealer protrudes from the workpiece.

  Even in this case, the sealer coating device is provided with a display device that displays the discharge angle calculated by the arithmetic unit, and the operator corrects the position of the coating robot manually while checking the discharge angle. However, the application robot may automatically correct the position so that the distance calculated by the arithmetic unit becomes the optimum value (predetermined value) for the sealer application without providing the display device.

(4) In the vehicle sealer coating apparatus described in (2) or (3),
The arithmetic unit calculates a gap between the sealer nozzle and the outer edge of the workpiece based on a distance from the outer edge of the workpiece imaged by the imaging camera to the crossing position of the slit light beam image.

  In the present invention, the calculation device calculates the gap between the sealer nozzle and the outer edge of the workpiece based on the distance from the outer edge of the workpiece imaged by the imaging camera to the crossing position of the slit light beam image. The application robot can be taught with higher accuracy while maintaining the gap with the outer edge within an appropriate range. As a result, for example, it is possible to prevent the sealer nozzle from interfering with the workpiece to be deformed or damaged.

  Even in this case, the sealer coating apparatus may be provided with a display device that displays the gap calculated by the calculation device, and the position of the coating robot may be manually corrected while an operator confirms the gap. However, the application robot may automatically correct the position so that the gap calculated by the arithmetic unit becomes the optimum value (predetermined value) for the sealer application without providing the display device.

(5) In the vehicle sealer coating apparatus described in any one of (1) to (4),
A tip end portion of the sealer nozzle is formed in a substantially L shape or a substantially J shape, and the discharge port is opened in a direction facing the sealer gun.

In the present invention, the tip of the sealer nozzle is formed in a substantially L shape or a substantially J shape, and the discharge port is opened in a direction facing the sealer gun. The sealer can be applied while the sealer gun is disposed at a position facing the workpiece with the workpiece interposed therebetween. Therefore, the vehicle sealer coating apparatus according to the present invention can dispose a sealer gun on the outside of the vehicle with respect to the workpiece while the workpiece is attached to the body of the vehicle, and can apply the sealer from the inside of the vehicle. The sealer can be applied in the process after the electrodeposition coating and before the intermediate coating.
Therefore, according to the present invention, it is not necessary to pre-cure (pre-cure) the sealer by heating prior to the shower cleaning performed immediately before the electrodeposition coating, and an expensive sealer corresponding to the pre-cure (pre-cure) (pre-cure sealer) ), And an inexpensive sealer can be used. Moreover, heating equipment for pre-curing and heating energy can be omitted, and the sealer cost can be greatly reduced.

(6) In the vehicle sealer coating apparatus described in any one of (1) to (5),
In addition to displaying the calculated value of the arithmetic device, the monitor device displays a determination result for each of the various calculated values and an overall comprehensive determination result.

  In the present invention, since the calculation device is provided with a monitor device that displays the calculation value of the calculation device and the determination result for each calculation value and the overall comprehensive determination result, the operator can calculate the calculation value displayed on the monitor device. And the determination results for each calculated value can be confirmed without omission. Therefore, the operator can prevent teaching mistakes of the coating robot. Further, since the monitor device displays the overall comprehensive determination result, quick teaching can be performed by first checking the overall comprehensive determination result with priority.

(7) A teaching method for a vehicle sealer coating apparatus according to (6),
A first step of registering a threshold value defining a range that constitutes a non-defective condition for the calculated value of the arithmetic device;
A second step of operating the application robot to move the position of the sealer nozzle to the vicinity of the teaching point;
A third step of adjusting the position of the sealer nozzle while confirming the various calculated values and determination results displayed on the monitor device;
And a fourth step of registering teaching data at the position of the sealer nozzle at which the comprehensive judgment result displayed on the monitor device is good.

In the present invention, since the first step of registering a threshold value that defines the range that constitutes the non-defective condition for the calculated value of the arithmetic device is provided, it is determined whether or not the position of the sealer nozzle is within the range that constitutes the non-defective condition of the sealer application. Can be clarified in quantity.
In addition, a second step of operating the coating robot to move the position of the sealer nozzle to the vicinity of the teaching point, and a step of adjusting the position of the sealer nozzle while checking various calculated values and determination results displayed on the monitor device. 3 steps, so that the position of the sealer nozzle for applying the sealer to the overlapped portion of the hemming process can be determined based on various calculated values and determination results displayed on the monitor device even if the position is not visible to the operator. Can be adjusted.
In addition, the fourth step of registering teaching data at the position of the sealer nozzle where the comprehensive judgment result displayed on the monitor device is good is provided, so that teaching mistakes of the coating robot can be prevented and at the same time accurate teaching can be performed. Is possible.
In addition, since teaching data is registered in the fourth step, when correcting the teaching accompanying a change in the shape of the workpiece, using the registered teaching data, the application result is confirmed from the beginning and the position of the defective part is corrected. This makes it possible to avoid troublesome teaching operations such as.
Therefore, according to the present invention, the coating robot can be taught quickly and accurately without requiring the skill of the operator.

  ADVANTAGE OF THE INVENTION According to this invention, the sealer coating device for vehicles which can calculate the position of the sealer nozzle with respect to a workpiece | work quantitatively and can teach an application | coating robot accurately, and its teaching method can be provided.

1 is a perspective view of a vehicle sealer coating apparatus according to an embodiment of the present invention. It is a detailed top view of the light image which the light source device shown in FIG. 1 irradiates on the workpiece | work surface. It is a monitor display example of the monitor apparatus shown in FIG. It is a schematic diagram which irradiates one slit light beam to a target object from a light source device. FIG. 5 is a relationship diagram between the amount of movement of the light source device and the amount of movement of the light image in the object in the view C shown in FIG. FIG. 5 is a relationship diagram between the amount of movement of the light source device and the amount of movement of the light beam image of the object in the slit light beam intersecting in a cross shape. It is process drawing showing the teaching method in the sealer coating device of the vehicle shown in FIG. It is a typical perspective view of the conventional sealer coating device. It is a principle figure of the teaching apparatus of the coating robot described in patent document 1. FIG. It is sectional drawing which apply | coats a sealer to the overlapping part of the hemming process formed in the position which cannot be seen from an operator.

  Next, a vehicle sealer coating apparatus and a teaching method thereof according to an embodiment of the present invention will be described in detail with reference to the drawings. First, the overall structure of the vehicle sealer coating apparatus according to the present embodiment will be described, and then the mechanism and teaching method for calculating the position data of the sealer nozzle using the light image in the sealer coating apparatus will be described. Finally, the function and effect of this embodiment will be described.

<Overall structure of sealer coating device>
First, the whole structure of the vehicle sealer coating apparatus according to the present embodiment will be described with reference to FIGS. FIG. 1 is a perspective view of a vehicle sealer coating apparatus according to an embodiment of the present invention. FIG. 2 shows a detailed plan view of a light beam image irradiated on the work surface by the light source device shown in FIG. FIG. 3 shows a monitor display example of the monitor device shown in FIG.

  As shown in FIGS. 1 and 2, the vehicle sealer coating apparatus 10 according to this embodiment includes a sealer on the surface side of the workpiece W in a state where the workpiece (vehicle door) W is attached to the body B of the vehicle V. This is an apparatus for disposing the gun 1 and applying the sealer S from the back side of the workpiece W to the overlapping portion W3 for hemming. The workpiece W is not limited to the vehicle door. For example, various lids attached to the body B such as a bonnet and a trunk are applicable.

  A vehicle sealer coating apparatus 10 includes a sealer gun 1 disposed on a workpiece surface side, and a coating robot 2 on which the sealer gun 1 is detachably mounted. A sealer nozzle 3 formed of a cylindrical pipe is attached to the sealer gun 1. The sealer nozzle 3 has a tip portion 31 formed in an approximately L shape, and can be inserted into a narrow gap formed by the workpiece W and the body B. The tip portion 31 may be formed in a substantially J shape. A discharge port 311 that is opened in a direction facing the sealer gun 1 is formed at the tip 31 of the sealer nozzle 3. The sealer S discharged from the discharge port 311 is applied to the hemming overlapped portion W3 and its periphery. FIG. 1 shows a state in which the sealer gun 1 and the sealer nozzle 3 are removed from the coating robot 2.

  The application robot 2 is an articulated robot arranged outside the vehicle. Two laser beam irradiation devices 41 and 42 (corresponding to the light source device 4) and one imaging camera 5 are detachably mounted on the arm tip of the coating robot 2 via a substantially rectangular mounting plate 6. ing. The laser beam irradiation devices 41 and 42 generate two laser beams LB1 and LB2 (corresponding to a beam and a slit beam) that irradiate the workpiece surface W1 with inclination angles α1 and α2, respectively. The inclination angles α1 and α2 are substantially the same. Both laser beams LB1 and LB2 are slit beams having a predetermined width, and cross at substantially right angles on the workpiece surface W1 to form cross-shaped slit beam images G1 and G2 (corresponding to beam images). The crossing position G3 of the slit beam images G1 and G2 is formed at a position corresponding to the hemming overlapped portion W3 where the sealer S is applied from the discharge port 311 of the sealer nozzle 3 and the periphery thereof. Slit ray images G11 and G21 indicated by broken lines are ray images formed on the work surface W1 when the laser light irradiation devices 41 and 42 are arranged at predetermined positions, and the reference position G31 is specified on the work surface W1. To do. Details of these will be described later.

  The imaging camera 5 is a CCD camera, for example, and captures slit light beam images G1 and G2 on the workpiece surface W1 formed by the laser beams LB1 and LB2. The imaging range of the imaging camera 5 is a range (a viewing range in FIG. 2) that includes the slit light beam images G1 and G2, the workpiece surface W1 that is the target of sealer coating, and the outer edge W2 of the workpiece W. The imaging camera 5 is arranged on the bisector of the two laser beams LB1 and LB2 that are imaged from the direction perpendicular to the workpiece surface W1 (in the direction of the arrow Q) and irradiated by the laser beam irradiation devices 41 and 42. The imaging direction of the imaging camera 5 (the direction of the arrow K) is formed in the direction opposite to the discharge direction of the sealer S (the direction of the arrow J) at the discharge port 311 of the sealer nozzle 3. Note that the imaging direction of the imaging camera 5 (the direction of the arrow K) and the ejection direction of the ejection port 311 (the direction of the arrow J) may be formed in the same direction.

The coating robot 2 is electrically connected to an arithmetic unit 7 that performs arithmetic processing on the imaging data of the slit ray images G1 and G2 captured by the imaging camera 5.
The computing device 7 discharges the sealer nozzle 3 based on the movement amount L3 that moves in the direction parallel to the workpiece surface W1 from the reference position G31 of the crossing position G3 in the slit ray images G1 and G2 captured by the imaging camera 5. The gap d1 between the outlet 311 and the hemming overlapped portion W3 is calculated. The reference position G31 in the slit beam images G1 and G2 is a crossing position of the slit beam images G11 and G21 corresponding to the optimum position of the sealer nozzle 3 that constitutes the non-defective condition of the sealer coating. The optimum position of the sealer nozzle 3 is set from the test results obtained by performing a sealer application test a plurality of times before teaching.

  The non-defective condition of the sealer application includes the discharge angle γ of the discharge port 311 with respect to the overlapping portion W3 in addition to the gap d1 between the discharge port 311 and the overlapping portion W3. As described above, the imaging direction of the imaging camera 5 (the direction of the arrow K) is formed opposite to the discharge direction of the sealer S (the direction of the arrow J) at the discharge port 311 of the sealer nozzle 3. Therefore, when the imaging direction of the imaging camera 5 (the direction of the arrow K) is perpendicular to the workpiece surface W1, the crossing angle β in the slit light beam images G1 and G2 is a right angle, and the ejection port 311 for the overlapping portion W3. The discharge angle γ is also a right angle. However, when the imaging direction of the imaging camera 5 (the direction of the arrow K) is inclined with respect to the workpiece surface W1, the crossing angle β in the slit beam images G1 and G2 becomes an acute angle or an obtuse angle, and the discharge port 311 for the overlapping portion W3. The discharge angle γ is also an acute angle or an obtuse angle. Here, the discharge angle γ of the discharge port 311 with respect to the overlapping portion W3 changes in proportion to the crossing angle β in the slit light beam images G1 and G2. Using this proportional relationship, the arithmetic unit 7 calculates the discharge angle γ of the discharge port 311 with respect to the overlapping portion W3 based on the crossing angle β in the slit ray images G1 and G2 captured by the imaging camera 5. Therefore, by confirming the crossing angle β in the slit beam images G1 and G2, it is possible to teach the coating robot 2 with higher accuracy while maintaining the discharge angle γ of the discharge port 311 with respect to the overlapping portion W3 within an appropriate range. it can.

  Further, the arithmetic unit 7 determines the gap d3 between the sealer nozzle 3 and the outer edge W2 of the workpiece W based on the distance d2 from the outer edge W2 of the workpiece W imaged by the imaging camera 5 to the crossing position G3 of the slit beam images G1 and G2. Is calculated. Therefore, by confirming the gap d3 calculated by the calculation device 7, the coating robot 2 can be taught with higher accuracy while maintaining the gap d3 between the sealer nozzle 3 and the outer edge W2 of the workpiece W within an appropriate range. . As a result, for example, the sealer nozzle 3 can be prevented from interfering with the workpiece W to be deformed or damaged.

  A monitor device 8 is electrically connected to the arithmetic device 7. As shown in FIG. 3, the monitor device 8 displays the calculated value calculated by the arithmetic device 7 and also displays the determination result for each calculated value and the overall comprehensive determination result. Specifically, the monitor device 8 includes a gap d1 (for example, 4.2 mm) between the discharge port 311 and the overlapping portion W3, a display field 81 of “OK” as the determination result, the sealer nozzle 3 and the workpiece W. A gap d3 (for example, 0.8 mm) with the outer edge W2 of the sheet, a display field 82 of “OK” as the determination result, a discharge angle γ (for example, 90 °) of the discharge port 311 with respect to the overlapping portion W3, and the determination. A display column 83 of “OK” as a result and a display column 84 of “overall determination OK” that is a determination result of the entire apparatus that combines various calculation results can be displayed by the monitor device 8.

<Location data calculation mechanism>
Next, in the vehicle sealer coating apparatus 10 according to the present embodiment, a mechanism for calculating the position data of the sealer nozzle from the image data of the light image captured by the imaging camera will be described with reference to FIGS. FIG. 4 shows a schematic diagram in which one slit beam is irradiated from the light source device to the object. FIG. 5 shows a relationship diagram between the amount of movement of the light source device and the amount of movement of the light ray image on the object in the view C shown in FIG. FIG. 5A shows a state in which the light source device is arranged at a position separated from the object by a predetermined distance, and FIG. 5B shows that the light source device is close to the object with respect to FIG. FIG. 5C shows a state in which the light source device is moved in a direction away from the object with respect to FIG. 5A. FIG. 6 is a diagram showing the relationship between the amount of movement of the light source device and the amount of movement of the light beam image on the object in two slit light beams that intersect in a cross shape.

  First, in order to simplify the description, a case where the light source device emits one slit beam as shown in FIG. 4 will be described. A light source device 4 that irradiates one slit light beam LB toward the work surface W1 is disposed at a position separated from the work surface W1 by a predetermined distance. The optical axis of the slit light beam LB forms an inclination angle α with respect to the workpiece surface W1. The light beam width of the slit light beam LB is formed so as to spread symmetrically with respect to the optical axis, and the light beam width is gradually expanded toward the tip side, but may be formed with a constant width.

  As shown in FIG. 5A, the light source device 4a is arranged at a predetermined position R with respect to the workpiece surface W1 with the optical axis inclined in the direction of the arrow L. The slit light beam LBa irradiated from the front end of the light source device 4a arranged at the predetermined position R at an inclination angle α forms a light image on the work surface W1 at the position K0.

  Next, as shown in FIG. 5B, the light source device 4b is moved in a direction closer to the workpiece surface W1 by the movement amount D1 (the direction of the arrow Q1) than the predetermined position R shown in FIG. The direction of the arrow Q1 is a direction perpendicular to the workpiece surface W1. The slit light beam LBb irradiated at the inclination angle α from the front end of the light source device 4b arranged at this moving position forms a light image on the workpiece surface W1 at the position K1. The position K1 of the slit light beam LBb moves downward (in the direction of the arrow P1) by the movement amount L1 from the position K0 of the slit light beam LBa. Here, the direction of the arrow P1 is a direction parallel to the workpiece surface W1, and the moving amount L1 of the light image is proportional to the moving amount D1 of the light source device.

  Further, as shown in FIG. 5C, the light source device 4c is moved in a direction away from the predetermined position R shown in FIG. 5A by the movement amount D2 (direction of arrow Q2) from the workpiece surface W1. The direction of the arrow Q2 is a direction perpendicular to the workpiece surface W1. The slit light beam LBc irradiated with the inclination angle α from the front end of the light source device 4c arranged at this moving position forms a light image on the workpiece surface W1 at the position K2. The position K2 of the slit light beam LBc moves upward (in the direction of the arrow P2) by the movement amount L2 from the position K0 of the slit light beam LBa. Here, the direction of the arrow P1 is a direction parallel to the workpiece surface W1, and the movement amount L2 of the light image is proportional to the movement amount D2 of the light source device.

As described above, when the light source device 4 is moved in the direction perpendicular to the workpiece surface W1, the positions K1 and K2 of the light image on the workpiece surface W1 are parallel to each other in proportion to the movement amounts D1 and D2 of the light source device 4. Move to.
As described above, the light source device 4 and the imaging camera 5 are attached to the tip of the arm of the coating robot 2. The imaging camera 5 captures an image from a direction perpendicular to the workpiece surface W1, and the ejection port 311 is formed so that the ejection direction J of the sealer S is opposite to the imaging direction. Therefore, the movement amounts D1 and D2 of the light source device 4 and the imaging camera 5 that move in the vertical direction with respect to the workpiece surface W1 are movements in which the discharge port 311 moves in the vertical direction with respect to the overlapping portion W3 on which the sealer S is applied. It corresponds to the amount.

  Therefore, the arithmetic unit 7 discharges the overlapping port W3 based on the movement amounts L1 and L2 that move in the direction parallel to the workpiece surface W1 from the reference position (K0) of the light image captured by the imaging camera 5. 311 vertical distances can be calculated. As a result, the coating robot 2 can be taught so that the distance calculated by the arithmetic unit 7 matches the optimum value (predetermined value) for sealer coating.

Next, as shown in FIG. 6, a case where two slit light beams crossing in a cross shape are irradiated will be described. The light source device 4 (laser light irradiation devices 41 and 42) of this embodiment shown in FIGS. 1 and 2 corresponds to this case.
The two slit beams are laser beams LB1 and LB2 irradiated by the laser beam irradiation devices 41 and 42 shown in FIG. The laser beams LB1 and LB2 irradiate the workpiece surface W1 with inclination angles α1 and α2, respectively. Cross-shaped slit light beam images G1 and G2 are formed on the work surface W1. Cross-shaped slit light beam images G11 and G21 indicated by broken lines are light beam images formed on the workpiece surface W1 when the light source device 4 (laser light irradiation devices 41 and 42) is disposed at a predetermined position.

  Slit light beam images G1 and G2 indicated by solid lines are formed on the work surface when the light source device 4 (laser light irradiation devices 41 and 42) is moved from a predetermined position in a direction closer to the work surface W1 by a movement amount D3. It is a ray image. In FIG. 6, for convenience, the workpiece surface W11 when the light source device 4 (laser light irradiation devices 41 and 42) is disposed at a predetermined position is indicated by a virtual line. Crossing position G3 in slit ray images G1 and G2 indicated by solid lines translates in the direction of arrow P1 with respect to reference position G31 formed on workpiece surface W11 indicated by virtual lines. The amount of movement L3 from the reference position G31 to the crossover position G3 is the amount of movement D3 by which the light source device 4 (laser light irradiation devices 41 and 42) moves in the vertical direction (the direction of arrow Q3), as in the case shown in FIG. Is proportional to

  Therefore, the arithmetic unit 7 discharges the overlapping portion W3 based on the movement amount L3 that moves in the direction parallel to the workpiece surface W1 from the reference position G31 of the slit ray images G1 and G2 captured by the imaging camera 5. The distance in the vertical direction 311 (for example, the gap d1) can be calculated. As a result, the coating robot 2 can be taught so that the distance calculated by the arithmetic unit 7 matches the optimum value (predetermined value) for sealer coating.

  Note that when the light source device 4 (laser light irradiation devices 41 and 42) is moved in a direction away from the workpiece surface W1 from a predetermined position, the slit beam images G1 and G2 formed on the workpiece surface are in the direction of the arrow P2. Translate to Therefore, by confirming in which direction the crossing position G3 of the slit beam images G1 and G2 is separated from the reference position G31, the distance in the vertical direction of the discharge port 311 with respect to the overlapping portion W3 (for example, Since the size of the gap d1) with respect to the optimum value (predetermined value) for the sealer application can be quickly determined, the application robot 2 can be taught quickly.

<Teaching method of sealer coating device>
Next, a teaching method in the vehicle sealer coating apparatus according to the present embodiment will be described with reference to FIG. FIG. 7 is a process chart showing a teaching method in the vehicle sealer coating apparatus shown in FIG.

As shown in FIG. 7, the teaching method in the sealer coating apparatus includes four steps (S1 to S4) described below.
The first step S <b> 1 is a step of registering a threshold value that defines a range that constitutes a non-defective condition for sealer application with respect to a calculated value of the arithmetic device 7. The calculated value of the arithmetic unit 7 includes a gap d1 between the discharge port 311 and the overlapping portion W3, a discharge angle γ of the discharge port 311 with respect to the overlapping portion W3, a gap d3 between the sealer nozzle 3 and the outer edge W2 of the workpiece W, and the like. Applicable. For example, since the gap d1 is about 4.0 to 6.0 mm, which is a non-defective condition for sealer application, 4.0 mm and 6.0 mm are registered as threshold values. By registering this threshold value, it is possible to quantitatively clarify whether or not the position of the sealer nozzle 3 is within a range that constitutes a non-defective condition for sealer application.

  Next, the second step S2 is a step of operating the coating robot 2 to move the position of the sealer nozzle 3 to the vicinity of the teaching point. The teaching point corresponds to a changing point on the locus of movement of the sealer nozzle when applying the sealer. Even when the teaching point is in a position where it cannot be seen from the operator, it is only necessary to move to the vicinity of the teaching point that is within the imaging range of the imaging camera, so that the operator can easily operate the application robot 2.

  Next, the third step S3 is a step of adjusting the position of the sealer nozzle 3 while confirming various calculated values and determination results displayed on the monitor device 8. Various calculated values and determination results are displayed in the display columns 81, 82, 83 of the monitor device 8, and can be simultaneously confirmed by the operator. Even if the sealer nozzle 3 is not visible to the operator, the operator can determine the position of the sealer nozzle 3 for applying the sealer to the overlapped portion W3 for hemming and various calculation values and determination results displayed on the monitor device 8. And can be easily adjusted based on.

Next, the fourth step S4 is a step of registering teaching data at the position of the sealer nozzle 3 where the comprehensive determination result displayed on the monitor device 8 is good. Teaching data is registered in the storage device of the application robot. As a result, teaching mistakes of the coating robot can be prevented, and at the same time, quick and accurate teaching can be performed. In addition, since teaching data is registered in the fourth step, when correcting the teaching accompanying the change in the shape of the workpiece W, by using the registered teaching data, the application result is confirmed from the beginning to locate the defective part. Troublesome teaching operations such as correction can be avoided.
Therefore, according to the teaching method in the vehicle sealer coating apparatus according to the present embodiment, the coating robot 2 can be taught quickly and accurately without requiring the skill of the operator.

If the sealer gun 1 is taught in a state where the sealer gun 1 is detached from the coating robot 2, the sealer coating apparatus 10 does not have to worry about the sealer nozzle 3 interfering with the workpiece W, and quick teaching is possible. It is not necessary to remove 1 from the coating robot 2.
In addition, the sealer coating apparatus 10 is provided with a display device that displays the distance calculated by the calculation device 7 (for example, the gap d1 between the discharge port and the overlapping portion), and an operator confirms the distance. Although the position of the coating robot 2 may be manually corrected, the coating robot 2 is automatically positioned so that the display device is not provided and the distance calculated by the calculation device 7 becomes the optimum value (predetermined value) for sealer coating. It may be corrected.

<Effect>
As described above in detail, according to the vehicle sealer coating apparatus 10 according to the present embodiment, the imaging camera 5 captures an image from the direction perpendicular to the workpiece surface W1 (the direction of the arrow Q), and the light source device 4 (Laser light irradiation devices 41 and 42) irradiate the work surface W1 with slit-shaped laser beams LB1 and LB2 from the tilt direction (the direction of arrow L) with respect to the imaging direction of the imaging camera 5 (the direction of arrow K). Therefore, when the coating robot 2 is operated to move the imaging camera 5 in the direction perpendicular to the workpiece surface W1, the positions of the slit light beam images G1 and G2 captured in proportion to the movement amount of the imaging camera 5 are obtained. It moves in a direction parallel to the workpiece surface W1.
Further, since the discharge port 311 is formed so that the discharge direction of the sealer S (the direction of the arrow J) is opposite (or the same direction) as the imaging direction (the direction of the arrow K), it is perpendicular to the workpiece surface W1. The amount of movement of the moving imaging camera 5 corresponds to the amount of movement of the discharge port 311 in the vertical direction with respect to the overlapping portion W3 where the sealer S is applied.
Further, based on the amount of movement in the direction parallel to the workpiece surface W1 from the reference position of the slit beam images G1 and G2 captured by the imaging camera 5, the distance in the vertical direction of the discharge port 311 with respect to the overlapping portion W3 ( For example, since the calculation device 7 for calculating the gap d1) is provided, the application robot 2 can be taught so that the distance calculated by the calculation device 7 matches the optimum value (predetermined value) for sealer application.

In addition, according to the present embodiment, the light source device 4 (laser light irradiation devices 41 and 42) emits two slit-shaped laser beams LB1 and LB2 that irradiate the workpiece surface W1 with the inclination angles α1 and α2, respectively. Since both the laser beams LB1 and LB2 cross within the imaging range of the imaging camera 5 (the range of view A in FIG. 2), the arithmetic unit 7 crosses the slit beam images G1 and G2 captured by the imaging camera 5. Based on the movement amount L3 that moves in the direction parallel to the workpiece surface W1 from the reference position G31 of G3, the distance in the vertical direction of the discharge port 311 with respect to the overlapping portion W3 (for example, the gap d1) can be calculated. . In this case, the arithmetic unit 7 can specify the light beam image captured by the imaging camera 5 as a point image at the crossing position G3 of the slit light beam images G1 and G2, so that the ejection port 311 in the vertical direction with respect to the overlapping portion W3. The distance can be calculated with higher accuracy.
The crossing position G3 in the slit light beam images G1 and G2 captured by the imaging camera 5 is a reference position G31 depending on whether the distance in the vertical direction of the discharge port 311 with respect to the overlapping portion W3 is longer or shorter than a predetermined value. Are separated in opposite directions (directions of arrows P1 and P2). Therefore, teaching of the coating robot 2 is performed quickly by determining in which direction the crossing position G3 of the slit beam images G1 and G2 captured by the imaging camera 5 is separated from the reference position G31. be able to.

  Further, according to the present embodiment, the computing device 7 calculates the discharge angle γ of the discharge port 311 with respect to the overlapping portion W3 based on the crossing angle β in the slit light images G1 and G2 captured by the imaging camera 5. The application robot 2 can be taught with higher accuracy while maintaining the discharge angle γ of the discharge port 311 with respect to the overlapping portion W3 within an appropriate range. As a result, for example, it is possible to prevent sealer application failure such that the sealer S protrudes from the workpiece W.

  Further, according to the present embodiment, the arithmetic unit 7 determines that the sealer nozzle 3 and the workpiece W are based on the distance d2 from the outer edge W2 of the workpiece W imaged by the imaging camera 5 to the crossing position G3 of the slit beam images G1 and G2. Since the gap d3 between the outer edge W2 and the outer edge W2 of the workpiece W is calculated, the coating robot 2 can be taught with higher accuracy while keeping the gap d3 between the sealer nozzle 3 and the outer edge W2 of the workpiece W within an appropriate range. As a result, for example, the sealer nozzle 3 can be prevented from interfering with the workpiece W to be deformed or damaged.

Further, according to the present embodiment, the tip 31 of the sealer nozzle 3 is formed in an approximately L shape, and the discharge port 311 is opened in a direction facing the sealer gun 1. It is possible to apply sealer while disposing the discharge port 311 and the sealer gun 1 at positions facing each other across the workpiece W. Therefore, the sealer coating apparatus 10 can dispose the sealer gun 1 on the outside of the vehicle with respect to the workpiece W and apply the sealer from the inside of the vehicle with the workpiece W attached to the body B of the vehicle V. For example, a sealer can be applied in a step after electrodeposition coating and before intermediate coating.
Therefore, according to the present sealer coating apparatus 10, it is not necessary to pre-cure (pre-cure) the sealer S by heating prior to shower cleaning performed immediately before electrodeposition coating, and an expensive sealer corresponding to pre-cure (pre-cure). An inexpensive sealer S can be used without using a (precure sealer). Moreover, heating equipment for pre-curing and heating energy can be omitted, and the sealer cost can be greatly reduced.

  In addition, according to the present embodiment, the monitor device 8 that displays the calculation value of the arithmetic device 7 and displays the determination result for each of the various calculation values and the overall comprehensive determination result is provided. 8 and the determination results for the various calculated values can be confirmed without omission. Therefore, the operator can prevent teaching mistakes of the application robot 2 in advance. Further, since the monitor device 8 displays the overall comprehensive determination result, it is possible to quickly teach by first checking the overall comprehensive determination result first.

Moreover, according to the teaching method of the sealer coating apparatus 10 for a vehicle according to another embodiment, the sealer nozzle includes the first step S1 for registering a threshold value that defines a range that constitutes a non-defective condition for the calculated value of the calculation device 7. It is possible to quantitatively clarify whether or not the position 3 is within the range that constitutes the non-defective condition of the sealer application.
In addition, the coating robot 2 is operated to move the position of the sealer nozzle 3 to the vicinity of the teaching point, while confirming various calculated values and determination results displayed on the monitor device 8. Since the third step S3 for adjusting the position is provided, the position of the sealer nozzle 3 for applying the sealer to the overlapping portion W3 for hemming processing is displayed on the monitor device 8 even if the position is not visible to the operator. Adjustment can be made based on the calculated value and the determination result.
In addition, since the fourth step S4 for registering teaching data is provided at the position of the sealer nozzle 3 where the comprehensive determination result displayed on the monitor device 8 is good, teaching errors of the coating robot 2 are prevented in advance, High-precision teaching is possible. In addition, since the teaching data is registered in the fourth step S4, the application result is confirmed from the beginning by using the registered teaching data when correcting the teaching accompanying the shape change of the workpiece W, and the defective portion is identified. Troublesome teaching operations such as correction can be avoided. Therefore, the application robot 2 can be taught quickly and accurately without requiring the skill of the operator.

<Modification>
The embodiment described above can be changed without changing the gist of the present invention.
(1) In the present embodiment, the tip portion 31 of the sealer nozzle 3 is formed in a substantially L shape, and the discharge port 311 is opened in a direction facing the sealer gun 1. There is no limit.
For example, the front end portion of the sealer nozzle may be formed in a straight line, and the discharge port may be opened in a direction facing the overlapping portion of the hemming process. In this case, the imaging direction of the imaging camera is the same as the application direction of the sealer.
(2) In the present embodiment, the two light source devices 4 (laser beam irradiation devices 41 and 42) are mounted on the coating robot 2, but the present invention is not necessarily limited thereto.
For example, only one light source device may be attached to the coating robot.

  INDUSTRIAL APPLICABILITY The present invention can be used, for example, in a vehicle sealer application device that applies a sealer to an overlapping portion of a vehicle door by hemming and a teaching method thereof.

DESCRIPTION OF SYMBOLS 1 Sealer gun 2 Coating robot 3 Sealer nozzle 4 Light source device 5 Imaging camera 7 Arithmetic device 8 Monitor device 10 Sealer coating device 31 Tip 41, 42 Laser light irradiation device (light source device)
311 Discharge port α, α1, α2 Inclination angle β Cross angle γ Discharge angle B Body d1 Clearance (distance)
d2 Distance d3 Gap D1, D2, D3 Movement G1, G2 Slit ray image (ray image)
G3 Crossing position G31 Reference position J Discharge direction K Imaging direction L Inclination direction LB Slit beam (ray)
LB1, LB2 Laser beam (beam, slit beam)
L1, L2, L3 Movement amount Q Vertical direction S Sealer d1, d3, γ Calculated value S1 First step S2 Second step S3 Third step S4 Fourth step V Vehicle W Work W1 Work surface W2 Outer edge W3 Overlapping part

Claims (7)

A sealer gun having a sealer nozzle having a discharge port formed at the tip, a light source device for generating a light beam to be irradiated on the workpiece, an imaging camera for capturing a light image irradiated on the workpiece by the light source device, and A sealer coating device for a vehicle that includes a coating robot capable of mounting a sealer gun, the light source device, and the imaging camera, and that applies a sealer from the discharge port to an overlapping portion of a hemming process formed on a workpiece,
The imaging camera captures an image from a direction perpendicular to a workpiece surface, and the light source device irradiates the light beam on the workpiece from an inclination direction with respect to an imaging direction of the imaging camera;
The discharge port is formed such that the discharge direction of the sealer is the same or opposite to the imaging direction,
An arithmetic unit that calculates a vertical distance of the ejection port with respect to the overlapping portion based on a movement amount that moves in a direction parallel to the work surface from a reference position of the light image captured by the imaging camera; A sealer coating apparatus for a vehicle, comprising: In the vehicle sealer coating apparatus according to claim 1,
The light source device generates two slit beams that irradiate the workpiece with an inclination angle, and both slit beams cross within the imaging range of the imaging camera. . In the vehicle sealer coating apparatus according to claim 2,
The calculation device calculates a discharge angle of the discharge port with respect to the overlapping portion based on a crossing angle in a slit beam image captured by the imaging camera. In the vehicle sealer coating apparatus according to claim 2 or 3,
The arithmetic unit calculates a gap between the sealer nozzle and the outer edge of the workpiece based on a distance from the outer edge of the workpiece imaged by the imaging camera to the crossing position of the slit beam image. Sealer applicator. In the vehicle sealer coating apparatus according to any one of claims 1 to 4,
A sealer coating apparatus for a vehicle, wherein a tip end portion of the sealer nozzle is formed in a substantially L shape or a substantially J shape, and the discharge port is opened in a direction facing the sealer gun. . In the vehicle sealer coating apparatus according to any one of claims 1 to 5,
A sealer coating apparatus for a vehicle, comprising: a monitor device that displays a calculated value of the arithmetic device and displays a determination result for each of the various calculated values and an overall comprehensive determination result. A teaching method for a vehicle sealer coating apparatus according to claim 6,
A first step of registering a threshold value defining a range that constitutes a non-defective condition for the calculated value of the arithmetic device;
A second step of operating the application robot to move the position of the sealer nozzle to the vicinity of the teaching point;
A third step of adjusting the position of the sealer nozzle while confirming the various calculated values and determination results displayed on the monitor device;
And a fourth step of registering teaching data at the position of the sealer nozzle at which the comprehensive judgment result displayed on the monitor device is good.

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