Wiping process in robotic paint repair

Abstract

A wiping system for a robotic repair unit is proposed, comprising a motorized robotic arm, a connection mechanism coupled to the motorized robotic arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The motor-powered motorized robotic arm moves the wiping medium. The motorized robotic arm is configured to move the wiping medium toward or away from a work surface. The motorized arm is configured to press the wiping medium toward the work surface during the wiping operation. The wiping medium is driven against the surface by the wiping motor during the wiping operation.

Description

Background Technology

[0001] The automotive industry typically requires preparing the surfaces of vehicle parts or replacement parts (e.g., bumpers) for various purposes (e.g., coatings), or repairing the surfaces of automotive parts or replacement parts due to defects introduced during painting or coating processes. Typical surface preparation processes include, for example, physical grinding or "scraping" of automotive surfaces. Typical repair operations typically include, for example, sanding and polishing. Surface preparation and the repair of defects on surfaces can utilize various tools, materials, and fluids. Summary of the Invention

[0002] A wiping system for a robotic repair unit is proposed. The system includes a motorized robotic arm, a connection mechanism coupled to the robotic arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The motorized robotic arm, powered by the motor, moves the wiping medium. The robotic arm is configured to move the wiping medium toward or away from a work surface. The robotic arm is configured to press the wiping medium toward the work surface during the wiping operation. The wiping medium is driven by the wiping motor to press against the surface during the wiping operation.

[0003] Removing process fluids or slurries during defect repair processes has proven beneficial to the final workpiece product and can be achieved by adding a fluid removal step after any grinding treatment. The limiting factor for wiping efficiency has been shown to be water removal. Wiping parameters should be selected to drain water from the pad, allowing it to operate close to steady-state for as long as possible in terms of water retention, while still removing a high percentage of slurry from the repair. This removal step previously required an operator to wipe the workpiece surface to remove the process fluids. By incorporating the first tool, second tool, and fluid removal tool all onto a single motorized robotic arm, potentially with a single force control unit, the process for efficiently repairing automotive surfaces is streamlined. Attached Figure Description

[0004] This disclosure can be more fully understood in conjunction with the accompanying drawings and the following detailed description of various embodiments thereof, wherein:

[0005] Figure 1 This is a schematic diagram of a robotic paint repair system, in which an embodiment of the present invention is useful.

[0006] Figure 2 This is a schematic diagram of a paint repair robot, in which an embodiment of the present invention is useful.

[0007] Figure 3 This is a schematic diagram of the dual-mounted end effector system of the paint repair robot according to the embodiment described herein.

[0008] Figure 4A and Figure 4B These are the image results from a haze quality experiment.

[0009] Figures 5A to 5B A dual-mounted end effector system with a fluid removal tool is shown according to an embodiment of this document.

[0010] Figure 6 The possible placement of the fluid removal tool on a dual-mounted end actuator system is shown.

[0011] Figure 7 An implementation of a fluid removal tool is shown.

[0012] Figure 8 A schematic diagram of a robotic repair system according to an embodiment of this document is shown.

[0013] Figure 9 A method for performing defect repair operations according to the embodiment described herein is shown.

[0014] Figures 10A to 10C illustrate wiping media according to embodiments described herein.

[0015] Figure 11A and Figure 11B A wiping system according to an embodiment of this document is shown.

[0016] Figures 12A to 12D A vacuum attachment for a fluid removal system according to an embodiment of this document is shown.

[0017] In the accompanying drawings, similar reference numerals indicate similar elements. While the foregoing drawings, which may be drawn not to scale, illustrate various embodiments of this disclosure, other embodiments as mentioned in the detailed description are also contemplated. In all instances, this disclosure is described by way of exemplary embodiments and not by way of limiting the scope of the disclosure. It should be understood that many other modifications and embodiments will arise for those skilled in the art, which fall within the scope and spirit of this disclosure. Detailed Implementation

[0018] This disclosure provides automated systems and methods for using a robotic repair unit with an end-effector system having mounting tools for treating (e.g., scraping, sanding, polishing, etc.) an object surface, and fluid, slurry, or debris removal tools that can be used before, after, and / or between these treatment steps. The treatment tools, together with the fluid removal tools, can be mounted on an end effector at the end of a motorized robotic arm, enabling them to move between various areas on the workpiece. The treatment tools may include functional components configured to contact and prepare the object surface; one or more sensors configured to detect operational status information of the end effector tool and a fluid dispenser while the functional components are contacting and preparing the object surface; and / or control circuitry for receiving and processing signals from the sensors to generate tool status information. The controller may also calculate the area wiped, such as the total number of uses, the duration of use, the saturation of fluid removal, and the rest period for drying. The fluid removal tools may also include one or more sensors configured to detect tool operational status information, a force control unit, or an end effector that allows the fluid removal tools to move against or apply force to the work surface.

[0019] Figure 1 This is a schematic diagram of a robotic paint repair system, in which embodiments of the invention are useful. System 100 typically includes two units, a visual inspection system 110 and a defect repair system 120, each of which may include sub-units. The two systems can be controlled separately by motion controllers 112 and 122, which can receive instructions from one or more application controllers 150. The application controllers can receive inputs or provide outputs to a user interface 160. Repair unit 120 includes a force control unit 124 alignable with an end effector 126. Figure 1 As shown, the force control element 124 can be coupled to any end effector 126, each end effector being coupled to the tool 128. In one embodiment, the tool 128 can be arranged as further described, such as those described in U.S. Provisional Patent Application Serials 62 / 940950 and 62 / 940960, filed November 2, 2019. However, other arrangements are also explicitly contemplated. The visual inspection unit 110 can detect defects on the vehicle surface 130, which can then be repaired by the repair unit 120.

[0020] Figure 2This is a schematic diagram of a paint repair robot that can be used in embodiments of the present invention. In some embodiments, the robotic repair unit 200 has a base 210, which may be fixed. In other embodiments, the base 210 may be movable about the x-axis, y-axis, and / or z-axis in any of six dimensions, translation, or rotation. For example, the robot 200 may have a base 210 fixed to a track system configured to travel with the vehicle being repaired, or it may be mounted on a wall or ceiling support. Depending on the location of the defect, the robot 200 may need to move closer to or further away from the vehicle, or it may need to move higher or lower relative to the vehicle. A movable base 210 can make repairing hard-to-reach defects easier.

[0021] The robotic repair unit 200 has one or more tools 256 that can interact with a work surface. In one embodiment, the tool 256 may include a support pad or another suitable abrasive tool. During the abrasive operation, the tool 256 may have an abrasive disc or other suitable abrasive article, which is attached using adhesives, hooks and rings, clamping systems, vacuum, or other suitable attachment systems. When mounted to the robotic repair unit 200, the tool 256 has the ability to be positioned within the degrees of freedom provided by the robotic repair unit 200 (in most cases, six degrees of freedom) and any other degrees of freedom in its reference frame (e.g., the compensatory stress control unit 230).

[0022] Figure 3 An embodiment of a dual-mounted end effector system 320 on a robotic arm 300 is shown. The robotic arm 300 can rotatably move the end effector system 320 using a mounting adapter plate 310 and vertically move the end effector system using a connector 315. In some embodiments, the robotic arm 300 is movable such that a first tool 330 or a second tool 340 can be positioned to interact with a workpiece. As shown, the system 320 uses a single force control unit mounted to the plate 310 to alternately operate the first tool 330 and the second tool 340. A first use position and a second use position align one of the tools 330, 340 with the force control unit.

[0023] During a paint or clear coat repair process, fluid may be applied to the workpiece before, during, or after the use of either tool 330 or 340. This process fluid may combine with particulate matter from the process to create a fluid slurry. The particulate matter constituting this slurry is typically generated by a sanding process, which usually occurs before the polishing step. Treatment by tool 330 or 340 without prior removal of this slurry fluid can have adverse effects on the final painted surface. These adverse effects include a blurred or unpolished appearance in the final painted product, or undesirable scratches or other damage, which can be caused by micro-scratches. The improvement seen upon removal of the slurry is unexpected, as removing the slurry before surface polishing is not standard practice for robotic repair systems. A blurred or defective appearance is not observed on every polished surface, but is most noticeable after the accumulation of sanding slurry or particulate matter on the polishing pad. Experiments conducted on clear coat workpieces have demonstrated the adverse effects of accumulation on the polishing pad.

[0024] Figures 4A to 4B These are images from a haze quality experiment. This experiment compared fluid removal and non-fluid removal defect repair processes on sanded and polished surfaces. To complete the experiment, surfaces from 4A were sprayed with water, sanded, and polished with small polishing beads in 12 consecutive cycles, with slurry fluid removed after each sanding step. Fluid removal was performed manually using a wiping technique. Images of the polished surface were captured after the 4th, 8th, and 12th sanding / polishing cycles, and are represented by 402, 404, and 406, respectively. Figure 4B The results of a similar 12-cycle sanding and polishing test without removing fluid after the sanding step are shown. The results after the 4th, 8th, and 12th sanding / polishing cycles are represented by 410, 412, and 114, respectively.

[0025] like Figure 4A and Figure 4B As shown, removing fluid between the sanding and polishing steps results in a reduction in haze on the paint surface appearance at the end of the repair process. Some manufacturers currently practice having operators manually remove the slurry after sanding and before the polishing step. This manual step is accomplished by wiping the workpiece with an absorbent material, such as a towel or sponge, to remove slurry or particulate matter that may cause defects in the final paint or clear coat product. As used herein, the term absorbent refers to a material that absorbs fluid upon contact with a solution or suspension. Absorbent materials may contain voids or channels that can trap fluid, or they may contain fibers designed to absorb moisture. Because many solutions used with abrasive materials are water-based, in some embodiments, absorbent refers to a hydrophilic material. Absorbent materials can be nonwoven or woven materials.

[0026] The current process, which involves manually wiping the workpiece surface after each sanding step, is time-consuming. The process time for automated coating polishing can be improved by streamlining or automating the fluid removal process steps.

[0027] It is believed that the wiping step can be completely removed when the robotic system takes over the defect repair process. This is because operators typically perform the wiping step to allow them to see the repair area for subsequent polishing steps; therefore, it is thought that the wiping step can be removed since the robot does not need to "see" the defect area to continue with the polishing process. However, as... Figure 4A and Figure 4B The comparison shows that when the wiping step is reintroduced, the surface finish of the robotic repair process is significantly improved after multiple defect repairs.

[0028] Figure 5A A sanding tool system 500 with dual mounting tools 502 and 504 is shown. In one embodiment, system 500 can be mounted to the end of the arm of a robotic repair unit. Tools 502 and 504 are coupled to end effectors 512 and 514, respectively. Both end effectors 512 and 514 are coupled to a force control unit (not shown in FIG. 5) attached to a mounting plate. System 500 is capable of rotating at least 180 degrees to allow tool 502 or tool 504 to contact the workpiece in a single operation. Each of tools 502 and 504 can be used for polishing, sanding, or other surface preparation purposes. The tool configuration of FIG. 5 also shows a fluid removal tool 506. In one embodiment, fluid removal tool 506 is coupled to sanding tool system 500 using fastener 508. In the embodiment shown in FIG. 5, fluid removal tool 506 is a passive removal tool that is dragged across the surface in contact with slurry fluid. Fluid removal tool 506 can be a cloth, sponge, or other wiping medium.

[0029] However, although Figure 5A A passive removal system is illustrated, but in other embodiments, the fluid removal tool 506 is an active fluid removal tool that includes a moving system, such as a vacuum or air knife. Similarly, while systems and methods relating to linear, unidirectional wiping processes are described herein, more complex motions, such as the motion of rotating, orbital, or random orbital devices, are explicitly removed.

[0030] In other embodiments, the fluid removal tool 506 is a semi-passive removal system, such as having a passive element 506 but an active moving element, such as a fastener 508 that can extend through a mechanical element. For example, the fluid removal tool 506 may include a spring or pneumatic compliance source to allow compliance with applied pressure or force. Alternatively, the fluid removal tool may be mounted such that it uses the same compliant tool to which a sander or polisher is mounted.

[0031] In some embodiments, the fluid removal tool 506 is positioned as part of the rotation path of the system 500, for example, such that the wiping medium 506 intersects the arc 520. This positioning allows the fluid removal tool 506 to contact the workpiece as the system 500 rotates between a first position where tool 502 interacts with the surface and a second position where tool 504 interacts with the surface. The fastener 508 can be a fixing member, or it can also be used to connect the fluid removal tool 506 to a force controller. In some embodiments, the fastener 508 is sized to position the fluid removal tool 506 on the rotation arc 520, thereby allowing the removal tool 506 to passively contact the workpiece surface as the robot switches between the active positions of tools 502 and 504.

[0032] Figure 5A An embodiment of the system 500 is shown, which is sufficient to remove sludge material on its own. A limiting factor for effective wiping operations is the removal of water absorbed by the wiping medium. If the wiping medium can reach a steady state or near a steady state, where similar amounts of water are drained from the pad, as absorbed in the wiping sludge, then the wiping medium can be used for a large number of wiping operations before needing to be replaced or treated.

[0033] Water can be drained in several ways. The friction generated by the contact between the wiping medium and the surface, or by rotating the wiping element between wiping operations, may be sufficient.

[0034] Wiping efficiency can be improved by keeping the robot's trajectory in contact with the outer part of the wiping pad and the abrasive slurry. Figure 5B A schematic diagram of wiping operation 550 is shown, in which wiping element 560 engages with slurry 552 formed during the repair of defect 554. It should be noted that the wiping element 560 is not centered within the slurry 552 or on the defect 564, but rather positioned off-center. Figure 5B As shown, the rotational speed increases from the center 564 of the wiping element 560 towards the edge 562. Therefore, higher friction is generated at the outer edge of the wiping element 560 compared to the center 564 where the speed is approximately zero, and thus higher heat is generated. The robot trajectory can be programmed such that the wiping element 560 circles inward toward the defect 564, such that the center 564 of the wiping element 560 does not engage the slurry, or only engages the slurry after the outer edge of the wiping element 560 has passed through the area. In some embodiments, it is not necessary to remove all the slurry 552, but only to sufficiently wipe the area of ​​the defect 554 so that it can be imaged and the repair of the defect 554 can be evaluated. In such embodiments, the wiping element 560 can be moved in direction 566 such that the outer portion of the wiping element 560 engages the slurry before the center 564.

[0035] Figures 5A to 5B An embodiment of the wiping element is shown in which it achieves steady-state or near-steady-state operation without external dehydration tools. However, as discussed herein, it is explicitly envisioned that the wiping element 560 may also be exposed to or include a vacuum source or heat source that causes the entrained water to evaporate.

[0036] The goal is to minimize wiping operation time as much as possible. Therefore, a combination of robot trajectory, heat source, vacuum source, applied force to generate friction, rotational speed, and / or air source can be used to reduce the time required to wipe away a sufficient amount of sludge from the defect area. The heat source may include a heating lamp (such as an infrared heating lamp) or another source. The air source may include an airflow, a fan, etc. A vacuum may be provided with or separately from the wiping element 560.

[0037] Figure 6 A robotic system with fluid removal tools according to an embodiment of this document is illustrated. System 600 may include tools 630 and 640 mounted on end effectors 620a and 620b, which are fixed or fastened to a force controller 660. Controller 660 is further fastened to a mounting plate 650, which is rotatable at least 180 degrees to properly position tools 630 and 640 for processing workpiece surfaces. The fluid removal tools described in this application may be fastened or mounted to end effectors 620a or 620b at attachment points such as 602, 604, and 606.

[0038] The fluid removal tool can be mounted, for example, in either tool position 630 or 640, such that a 180-degree rotation of the mounting plate 650 interchanges the relative positions of tools 630 and 640. As part of this movement, in some embodiments, the fluid removal tool can move through the defect repair area.

[0039] In one embodiment, the fluid removal tool may be mounted generally perpendicular to the two tools 630, 640. This positioning facilitates passive wiping or surface cleaning as the mounting plate 650 rotates during switching from tool 630 to 640. It may also be advantageous to size the tool mount such that the fluid removal tool is positioned on a radial arc of rotation to facilitate passive or semi-passive wiping.

[0040] In one embodiment, passive wiping involves providing contact between the wiping medium and the workpiece surface solely through rotation of the mounting plate 650, without the need for additional robot or force controller movement.

[0041] In another embodiment, semi-passive wiping includes providing contact between the wiping medium and the workpiece surface during rotation of the mounting plate 650, but also requires any additional amount of force or movement from the fluid removal tool to facilitate effective contact with the workpiece surface.

[0042] Semi-passive wiping may also include providing the wiping medium along a trajectory such that the outer region of the wiping medium engages the defect area first and entrains more fluid than the inner portion of the wiping medium. Semi-passive wiping may include selecting the rotational speed, applied force, and lateral movement speed of the wiping medium when it contacts the surface being wiped. Semi-passive wiping may also include a heat source, air source, or vacuum that facilitates fluid removal.

[0043] In another embodiment, active wiping may include an additional robotic system or arm to facilitate contact between the fluid removal tool and the wiping system. Active wiping may include contact between the fluid removal tool and the wiping system that does not occur during rotation of the mounting plate 650. Active wiping may include a pneumatic or other motion tool that moves the fluid removal tool.

[0044] In addition, active wiping may include another fluid removal aid, such as a heat source, air source, or vacuum, which is provided when the wiping medium contacts the surface or to the wiping medium between wiping operations.

[0045] When determining the placement of fluid removal tools, the sensor, wiring, and piping requirements of System 600 must be considered. Passive removal tools (such as wiping media) may be easier to place than active fluid removal tools, which may have additional mechanical requirements. For example, an air knife fluid removal tool may require a sufficient supply of clean, dry air or vacuum. Fluid removal tools using Force Control Unit 660, another Force Control Unit, or with additional sensor capabilities may have different alignment requirements.

[0046] Automating fluid removal processes presents several challenges compared to the manual processes currently used in industry. One major issue is ensuring adequate slurry removal. Operators can observe the work surface during the wiping process to verify that fluid or slurry has been effectively removed. While robotic fluid removal systems may include optical sensors to provide similar feedback, the timing allocated to wiping operations is detrimental to iterative feedback systems because each added second increases the required dwell time, thus reducing the number of repairs that can be completed within a shift. Additionally, as... Figure 6 As shown, the space available on the end-of-arm system 600 is limited, and additional sensors further reduce the space available for tooling. Due to the difficulties associated with incorporating additional sensors, in some embodiments, an efficient and predictable fluid removal system that does not require visual verification is incorporated into the end-of-arm system 600.

[0047] The operator also has the ability to adjust the applied pressure and use random hand movements (e.g., circular and linear wiping patterns), and to adjust or repeat the process as needed. These variations in pressure and wiping techniques allow the operator to clean the workpiece surface effectively and reliably. Programming such unstable movements on robot mating parts is difficult.

[0048] Another variable the operator considers is the saturation of the wiping medium. When the wiping medium becomes saturated, the operator can perform maintenance adjustments to expose unsaturated surface areas and facilitate more efficient fluid removal. The operator may also be able to detect when the wiping medium needs to be replaced based on saturation. The operator can also use very large wiping materials (i.e., large towels) that are difficult for robots to handle. Moreover, the operator can quickly discard and pick up new wiping material, where the robot has much longer time to complete this change. This paper describes several systems and methods for addressing these challenges.

[0049] Therefore, it may be desirable to select operating parameters that allow the wiping medium to approach or achieve steady-state operation. This could include automating the slurry dispensing process so that a known amount of fluid is consistently distributed. The operation of the wiping system can then be calibrated so that a known amount of fluid can be removed from the surface and then evaporated or otherwise removed from the wiping medium during each wiping cycle. This could include adjusting the rotational speed, lateral speed, or applied force of the wiping medium. It could also include selecting a trajectory for the wiping medium such that most of the absorbed fluid is entrained in the outer portion of the wiping medium.

[0050] Figure 7 A fluid removal system 700 for an end-of-arm robotic repair unit is shown. The fluid removal system 700 also allows wiping media to be exposed for on-demand wiping of surfaces. In some embodiments, the wiping media is an unsaturated wiping media, such as uncontaminated, unused, or fresh wiping media or a portion thereof. In some embodiments, the wiping media is a previously used wiping media, such as one that has been cleaned, debrided, or not yet saturated with sludge material. The wiping media can continue to be used as long as it is sufficient to remove sludge and debris from the surface. In some embodiments, the wiping media is effective as long as at least 70% of the sludge material is removed during operation. In some embodiments, removal of at least 75% of the sludge material is required for effectiveness, or at least 80%, at least 85%, at least 90%, at least 95%, at least 98%, or at least 99%.

[0051] In some implementations, the wiping motion releases the wiping medium 720 from the first roller 710a, so that a new portion of the wiping medium 720 is exposed for the next wiping motion.

[0052] In another embodiment, the wiping medium is periodically or continuously unrolled from roller 710a and rolled onto roller 710b.

[0053] In one embodiment, system 700 is mounted to the end of an arm system for robotic repair, the end extending, for example, perpendicular to the dual mounting handling tools 712, 714. In one embodiment, fluid removal system 700 includes a fluid wiping medium 720 extending from a first roller 710a to a second roller 710b. In one embodiment, the wiping medium 720 is under tension maintained by a support rod 706 and a support node 702. The node 702 forms a vertex in the wiping medium, which serves as a contact point with the workpiece surface; in some embodiments, the shape of the node 702 may vary depending on factors such as the wiping medium.

[0054] In one embodiment, the support rod 706 is coupled to a motion controller (704) that moves the node 702 in directions 732 and 734. This directional control allows the motion controller to be programmed to move the wiping medium 720 in a complex motion manner, which allows the fluid removal system 700 to remove fluid more efficiently. For example, it has been determined that fluid must be removed from defect areas between sanding and polishing steps. However, not all fluid needs to be trapped on the wiping medium 720. For example, movement of the support rod 706 and the node 702 in direction 736 can cause fluid to be flung out or ejected from adjacent defect areas.

[0055] exist Figure 7 In the illustrated embodiment, the wiping medium extends from the rolling tool 710a to 710b, such that the wiping medium 720 rolls out from one rolling tool (e.g., 710a), crosses node 702, and wraps around a receiving tool (e.g., 710b). This circulation of the wiping medium allows for the supply of fresh or unsaturated wiping medium 720 to contact the workpiece surface, after which contaminated medium 720 is rolled onto 710b.

[0056] In one embodiment, system 700 further includes a debris removal tool 722 that can remove a portion of the slurry or debris from the medium after it has been used and before it is rewound. The debris removal tool 722 can be, for example, a scraping, brushing, or impacting tool for removing dried, crusted slurry. In some embodiments, the wiping medium can be a continuous strip wound around both sides of the rolling tools 710a / 710b. In another embodiment, the debris removal tool 722 may also consist of a more mechanical device, such as an air knife, vacuum, or flushing tool. Such a mechanical tool 722 can effectively remove dried particulate matter.

[0057] Figure 8A schematic diagram of a robotic repair system 800 is shown. According to embodiments herein, the robotic repair system 800 can be used to sand and polish defects on a work surface. In some embodiments, the work surface can be a vehicle, such as a car, sedan, truck, boat, airplane, helicopter, etc.

[0058] In one embodiment, the robotic repair system 800 includes an optical sensor 804 for locating paint / clear coat defects or areas to be repaired. The robotic repair system 800 also includes a robotic movement mechanism 808 for moving an arm-end assembly near the defect repair area. Figure 8 As shown, in one embodiment, the robotic repair system 800 includes a controller 830 that controls the movement and sensing of the robotic arm 810 and associated components. However, it is explicitly envisioned that in some embodiments, the robotic arm 810 and / or the components mounted thereon have their own controllers that receive and execute movement and sensing commands from the controller 830.

[0059] In some embodiments, an end-effector assembly is located at the end of the robotic arm 810, which may include various tools, such as those shown in Figures 5 to 6. Figure 7 And as shown in Figures 10 to 12. However, as Figure 8 As shown, it is clearly envisioned that in other embodiments, some components may be located elsewhere on one or more motorized robotic arms 810.

[0060] A first grinding tool 842 may be mounted on a robotic arm 810. In some embodiments, the first grinding tool is coupled to a first end effector 840. In some embodiments, a second grinding tool 848 is mounted to the robotic arm 810. The second tool 848 may be coupled to a second end effector 846. A fluid removal mechanism 860 may be mounted to the robotic arm 810. However, it is explicitly envisioned that in some embodiments, some of these components may be mounted on more than one robotic arm 810. For example, the first robotic arm 810 may support the first grinding tool 842, such as a sanding robot with a sanding tool, and the second robotic arm 810 may support a second grinding tool, such as a polishing robot with a polishing tool.

[0061] In one embodiment, the robotic arm 810 is moved to the appropriate position via an arm moving mechanism 816. In another embodiment, the grinding tools 842, 848 and the fluid removal system 860 may also be moved to the appropriate position via the arm moving mechanism 816, or each may have its own moving mechanism that moves them to the appropriate position on the workpiece surface.

[0062] The force control unit 812 may also be located on the robot arm 810 to control the interaction between the robot arm 810, the end effector system and the workpiece surface.

[0063] In some implementations, air lines 814 and fluid distributors 826 are fed from the robotic arm 810 to the end effector system to provide the necessary air and fluid supply for operating the first tool 842 and the second tool 848.

[0064] In some embodiments, the fluid removal tool 850 is also coupled to a force control unit 812. The fluid removal tool 850 may be, for example, a fabric-based wiping medium, an air knife, a vacuum system, or another suitable tool. However, it is also contemplated in some embodiments that the fluid removal tool 850 is coupled to a force control unit separate from the force control unit used for tool 842 or tool 848. It is also contemplated in other embodiments that the fluid removal tool 850 is a passive tool without an associated force control unit. In some embodiments, the fluid removal tool 850 is mounted in a fixed position on the robotic arm 810. In some embodiments, a fastener 852 may be used to secure the fluid removal tool 850 in a position that allows passive wiping. In some embodiments, the fastener 852 may be extendable or coupled to the force control unit 812 to facilitate semi-passive wiping.

[0065] The robotic arm 810 may also include a fluid removal compliance device 856 that provides force compliance to the fluid removal tool 856. The fluid removal compliance device 856 may be a passive compliance device, such as a flexible or compressible material that pushes the wiping medium against a work surface. In other embodiments, the fluid removal compliance device 856 is a mechanical device, such as a mechanical spring or a pneumatic cylinder.

[0066] In some implementations, the fluid removal tool 850 may be moved through space using a fluid removal mover mechanism 854. The mover mechanism 854 controls variables such as the pitch, tilt, and yaw of the active wiping motion of the fluid removal tool 850. A robot trajectory generator 809 generates a trajectory for the fluid removal tool 850 and / or the fluid removal conforming device 856, such that the outer portion of the surface area of ​​the fluid removal tool 850 encounters the fluid-containing area of ​​the surface.

[0067] In some embodiments, the fluid removal tool 850 may function in conjunction with a fluid removal force control unit 858. The force control unit 858 maintains appropriate force or pressure between the fluid removal tool 850 and the workpiece. The fluid removal force control unit 858 may be mounted to a robotic arm 810 and provides signals or control to the fluid removal tool 850 via fasteners 852. In other embodiments, the pressure or tension on the workpiece surface is regulated by a fluid removal compliance device 856.

[0068] In some implementations, the fluid removal tool 850 may function in conjunction with a fluid removal repair device 860. The repair device 860 may be a vacuum, brush, or scraper for removing particulate matter, debris, liquid, or slurry from the wiping medium of the fluid removal tool 850. The repair device 860 may also be a heat source, air source, or other water evaporator. For example, between wiping operations, the fluid removal tool 850 may be positioned near a heating lamp or fan. The repair device 860 may help provide suitable absorbent wiping medium and effective wiping medium for cleaning workpiece surfaces more than once.

[0069] In another embodiment, the fluid removal tool 850 may include replaceable components, such as a new absorbent pad when the old absorbent pad becomes saturated with fluid or debris. A fluid removal replacement mechanism 862 facilitates the replacement of the wiping medium fluid removal tool 850. In some embodiments, the replacement mechanism 862 is a release clamp, button, or hook system for quickly replacing saturated or depleted wiping medium.

[0070] However, in some implementations, the fluid removal tool 850 is designed to operate at a substantially steady state, allowing a single fluid removal tool to perform a large number of wiping operations, such as more than 10, 50, or even more than 100 operations, before needing to be replaced. This can be achieved by operating the robotic system 800 to cause the fluid removal tool 850 to release as much fluid as it absorbs during the wiping operation. Fluid can be removed from the fluid removal tool 850, for example, using a secondary fluid removal tool 851 (such as a heat source, airflow source, or vacuum source) applied during or between subsequent wiping operations. Fluid can also be removed by heat generated by friction between the fluid removal tool 850 and its abutting surface. Alternatively, fluid absorption can be controlled by moving the robot trajectory generator 809 of the fluid removal tool 850 so that the fluid is entrained in the outer region of the fluid removal tool 850, where higher rotational speeds generate more friction and thus more heat, which will help release the entrained fluid through evaporation or centrifugal force.

[0071] Figure 9A method for repairing a defective area on a working surface according to an embodiment of the present invention is shown. Method 900 can be used with any system described with respect to Figures 5 to 10. However, method 500 can also be implemented with another suitable robotic repair system.

[0072] In box 910, as shown in box 912, the surface repair system images the workpiece to identify and locate defects for repair, such as blemishes on a painted or clear coat surface. A motorized robotic arm can then be positioned to approximate its location, and the end-of-arm system is placed over the defect area to allow tool access to the workpiece, as shown in box 914. Defect detection may also include other detection and localization methods or steps, as shown in box 916. Imaging the surface and moving the robot to the appropriate position can be performed using a series of sensors and motion controllers, such as… Figure 8 Those described in the text.

[0073] In box 920, the robotic repair system places a first tool in place to repair the detected defect. This may include moving a sanding tool in contact with the surface. The first tool is used to process the workpiece. Surface treatment of the workpiece typically involves the dispensing 922 of a fluid, such as water or an abrasive or polishing solution used in the treatment. Sanding the surface typically produces a particulate slurry or suspension on the working surface.

[0074] In box 930, fluid is removed from the work surface. Fluid removal can occur when the arm-end assembly changes position from the first position to the second position. The fluid removal step is intended to remove the workpiece surface prior to the second grinding step. In some embodiments, as indicated in box 932, this fluid removal step can be achieved using passive contact, such as dragging a cloth or sponge across the surface. In some embodiments, as indicated in box 934, fluid removal includes semi-passive contact, such as applying force or moving a sponge or cloth across a moving portion of the work surface. In some embodiments, as indicated in box 936, fluid removal includes active contact, such as vacuum, air knife, or other active wiping mechanisms.

[0075] Passive fluid removal steps allow the fluid removal tool to contact or interact with the workpiece surface during the transfer of the end-arm component robot without requiring additional input or movement from the force controller or motion controller. In some embodiments, the fluid removal tool may be fixed in a suitable position within the robot's rotational domain to facilitate such contact. Partial passive fluid removal steps may occur during the transfer of the end-arm component robot, but may require additional input or movement from the force controller or motion controller.

[0076] In some methods, after the workpiece is first processed in a first position (e.g., box 940), the robot will move to a second robot position (e.g., box 940) in between, during which a fluid removal step is performed.

[0077] In some implementations, removing fluid from a work surface may involve operating a fluid removal tool under or near-steady-state conditions of water absorption. If a steady state is reached regarding the water entrained within the fluid removal tool, the lifespan of replaceable components (such as pads, brushes, or other absorbent materials) will be significantly extended. The pad can then be replaced based on the load of polishing material and abrasive debris or the wear of the pad itself. Conversely, if the pad must be replaced based on the entrained fluid, it must be replaced every few cycles. Selectable robot operating parameters include the lateral and rotary traverse speeds of the fluid removal tool, the force applied to the fluid removal tool, the amount of fluid dispensed, and the use of secondary fluid removal tools (such as heat sources, air sources, or vacuum sources).

[0078] In some implementations, a steady-state or near-steady-state is also explicitly envisioned for polishing. As the water in the polishing material evaporates, it leaves behind polishing particles, which then become dry and loose and can be removed by tapping the pad, allowing the pad to rotate freely, or by the pad moving or rotating against the surface in other ways.

[0079] In box 940, the robotic repair unit may be positioned in a second position, such that the second tool interacts with the workpiece. For example, after a sanding step, polishing of the work surface may be necessary, as indicated in box 942. In some embodiments, imaging of the work surface after the fluid has been removed may also be useful, as indicated in box 946. The second position may also facilitate replacement of the wiping medium, as indicated in box 944, for example, replacing a saturated wiping medium with a new or less saturated replacement. Other actions that may be performed by the robotic repair unit are also envisioned, as indicated in box 948.

[0080] The fluid removal tool of this invention can be a sponge or cloth-like material used as the wiping medium. A wiping medium with high absorbency should be selected to maximize the efficiency of removing slurry from the workpiece surface. The wiping medium should also have high saturation capacity to prevent poor or inefficient fluid removal. Wiping media made of channeled or woven materials can provide improved slurry capture and produce a cleaner workpiece surface with fewer streaks. The wiping medium can be integrated with a force controller and fastened to an end actuator, or it can be fastened with a pneumatic, spring, or other compliant system to ensure an ideal pressure distribution on the workpiece surface.

[0081] Figures 10A to 10C are examples of possible wiping media used as fluid removal tools. Figure 10A-1The medium 1000 shown has a surface including raised bumps that form lining channels such as those indicated by line 1002. Wiping the surface with the medium 1000 in a single motion leaves material in the line in which the channel 1002 moves across the surface. Conversely, the medium 1000 can be rotated such that it is pulled along the surface relative to the channel 1002 at an angle, as indicated by arrow 1010. However, other angles are explicitly contemplated; for example, any angle from 5° to 175° may be suitable. The performance of the medium 1000 can be... Figure 10A-4 As seen in [the image], two orientations of the medium 1000 were tested, including, for example... Figure 10A-2 The straight orientation shown and Figure 10A-3 The angular orientation is shown. For example... Figure 10A-4 As shown, both straight orientation and angled orientation removed some of the slurry mixture; however, the angled orientation performed better. Slurry material captured in channel 1002 of medium 1000 with a straight orientation left streaks.

[0082] exist Figure 10B The image shows a wiping medium 1020. Medium 1020 includes rows 1022 of raised portions offset from adjacent portions, such that no channels exist. Wiping medium 1020 may be superior to medium 1000 because it is more likely to leave less residue.

[0083] Figure 10C shows wiping medium 1040, which demonstrates a wiping material without obvious channels or protrusions. Wiping media 1000, 1020, and 1030 are all microfiber materials. However, similar results can be seen with other fabrics. Microfiber materials may be preferred, however, because they have higher absorbency than other fibers. As used herein, microfiber refers to fine synthetic textile fibers, typically having a finer fiber density than 1 denier. Microfibers can be made from polyamide, polyester, polypropylene, or another suitable material. Microfibers can be extruded and mechanically or chemically treated to break them into finer particles, which can generate a positive charge within the fiber. The fibers are then woven into flat or loop-woven fabrics. Loop-woven microfibers may be preferred because the fabric web may be better able to remove and absorb debris and fluids.

[0084] Microfiber materials are typically measured in grams per square meter (GSM), a measure of density, but are often referred to as weight. In some embodiments described herein, the microfiber wiping medium is at least 200 GSM, or at least 250 GSM, or at least 300 GSM, or at least 350 GSM, at least 400 GSM, at least 500 GSM, or even denser. Figure 10A and Figure 10B It shows a ratio Figure 10C-1 Lower pile knitted fabrics, Figure 10C-1 A higher pile knit fabric 1030 is shown. For example... Figure 10C-2 As shown, the higher pile knit fabric 1030 exhibits improved wiping when used in a straight or angled orientation.

[0085] However, while a straight or angular orientation is described for comprehension purposes, other movements are explicitly envisioned as possible, such as tools capable of rotation, orbital, or random orbital movement coupled to the wiping medium.

[0086] An improvement in wiping quality is observed as the available surface area increases, and this increase is related to an increase in the fluff or length of the fibers in the loop portion of the loop-woven fabric. Furthermore, the number of wiping operations increases with the increase in available surface area. For example, wiping medium 1000 becomes saturated after 5 sanding repair operations.

[0087] However, up to 2000 defect repair operations can be performed in a given work shift. A wiping solution is desired that can last for most of the work shifts without requiring replacement.

[0088] One possible solution is to increase the size of the wiping medium. For example, operators typically use polishing pads much larger than the sanding tools used in robotic repair units. However, smaller wiping units are preferred because the defects being repaired may be on wavy surfaces. The wiping unit should be able to fit into the contours of the vehicle body. Preferably, the wiping unit has a coverage area similar to that of the sanding or polishing tools used in robotic repair units.

[0089] It has been found that rotating the wiping tool upon contact with the work surface generates sufficient heat to allow at least a portion of the removed moisture to evaporate. Furthermore, it has been found that the cycle time required to remove fluid is significantly reduced when the wiping material is rotated compared to simply translating it across the slurry. Therefore, it has been found that the wiping area of ​​the wiping tool can be smaller, and the tool can still perform a large number of wiping operations without becoming completely saturated. For example, by generating sufficient heat to evaporate the entrained fluid, the amount of slurry that can be removed from the surface by a single wiping tool can be significantly increased, thereby increasing the number of sanding operations that can be performed. Even near-steady-state operation regarding liquid absorption can be achieved, for example, by evaporating almost as much or as much of the entrained liquid as absorbed during the operation.

[0090] Figure 11A and Figure 11BA wiping system according to an embodiment of this document is illustrated. The wiping system 1100 includes an absorbent wiping unit 1110 coupled to a motorizing unit 1102. The motorizing unit 1102 may be capable of moving closer to or further away from the work surface in the z-axis direction. Z-axis movement can be achieved using an electric or pneumatic motor that moves the wiping unit closer to or further away from the robotic arm. The motorizing unit 1102 may be coupled to a compliance unit 1104, which may be directly coupled to the wiping unit 1110. In some embodiments, the compliance unit 1104 may be a support pad, or as... Figure 11A The compliant interface pad is shown. The motor unit 1102 may also be able to rotate, for example, as indicated by arrow 1108.

[0091] The absorbing wiping unit 1110 may be characterized by having a backing 1118 with multiple protrusions 1106. For example... Figure 11A As shown, the backing 1118 may have a width approximately the same as the width of the compliant unit 1104. For example... Figure 11A As shown, in some embodiments, the wiping unit 1110 is a microfiber fabric wiping material composed of a plurality of microfiber strands woven to form protrusions 1112, each of these microfiber strands having a length 1116 and a diameter 1114. Figure 11A As shown, the length 1116 is greater than the diameter 1114. In some embodiments, the length 1116 may be less than 10x larger than the diameter 1114. However, as... Figure 11B As shown, in some embodiments, the length 1116 is more than 10x greater than the diameter 1114. The surface area obtainable using the wiping unit 1110 is much larger than that obtained using the wiping medium 1000, 1020, or 1030 coupled to the compliant unit 1104.

[0092] When compared with wiping media 1000 and 1030, wiping unit 1110 continued for 200 debris repair operations without saturation.

[0093] In addition to increasing the surface area, the wiping system 1100 can also increase the number of continuous repair operations that can be performed without saturation in two other ways through rotation and heat generation.

[0094] In some embodiments, system 1100 can move in the z-direction such that as the motor unit 1102 rotates, the protrusion 1112 is pressed into the surface by the compliant unit 1104. This generates friction, which can provide sufficient heat to cause some of the absorbed liquid to evaporate. Additionally, rotation can continue as the motor unit 1102 is raised away from the working surface, which can eject some liquid or debris from the protrusion 1112.

[0095] The number of repair operations can be increased by periodically brushing, knocking off, or otherwise removing debris from the wiping unit 1110, for example by brushing the protrusion 1112 against a rough surface, a bristled brush, or another surface.

[0096] In some embodiments, operation near steady state can be achieved, wherein approximately the same amount of fluid is absorbed and evaporated or knocked away during each new wiping operation. Reaching or near steady state may simply mean absorbing water such that the same amount of water absorbed as part of the sludge is discharged due to evaporation from the wiping unit 1110. In water-steady-state operation, debris may still accumulate on the surface of the wiping unit 1110. In other embodiments, the wiping unit 1110 continues for more than 100 wiping operations, or more than 200 wiping operations, or more than 300 wiping operations, or more than 500 wiping operations, or more than 1000 wiping operations when steady state is not achieved.

[0097] In some implementations, the effectiveness of the wiping unit 1110 can be measured based on the amount of slurry or debris removed from the working surface before the wiping unit 1110 becomes saturated or no longer sufficiently removes debris from the working surface.

[0098] When the wiping unit 1110 is sufficiently saturated with debris, it can be replaced or repaired. Replacement may include removing the wiping unit 1110, for example by detaching it from the compliance pad 1104, so that a new or repaired wiping unit 1110 can be attached. For example, a hook-and-loop attachment may be used between the wiping unit backing 1118 and the compliance unit 1104.

[0099] In some embodiments, servicing the wiping unit 1110 may include running it through a washing or drying cycle after it has been removed from the compliant pad 1104. However, in some embodiments, when the wiping unit 1110 is coupled to the motor unit 1102, at least some servicing may be performed, such as by engaging a rough or bristled surface to remove dry debris from the surface of the protrusion 1112.

[0100] Figure 11B Another embodiment of the wiping assembly 1150 is shown, wherein the wiping unit 1160 is attached to the motorized arm 1152. The wiping unit 1160 has a backing with a width 1162, the size of which is similar to the width at the point where the wiping unit 1160 is attached to the motorized arm 1152. The motorized arm 1152 may be able to move the wiping unit 1160 in the z-direction, for example, moving downward toward the surface and upward away from the surface. The motorized arm 1152 may also be able to rotate, for example, as indicated by arrow 1168.

[0101] The wiping unit 1160 includes several strands extending from the backing, each strand having a strand length 1164. Figure 11B An embodiment is shown in which the strand has a length of 1168 greater than the strand thickness dimension by 10x.

[0102] Wiping systems 1100 and 1150 in Figure 11A and 11B While shown separately, it is explicitly envisioned that in some embodiments, one or more tools or fluid dispensers are mounted on the same motorized robotic system as the wiping systems 1100, 1150.

[0103] As described above, the wiping systems 1100 and 1150 are advantageously positioned on a motorized robotic arm so that they do not add significant time to the repair process. Therefore, in some embodiments, it may be advantageous to position the wiping systems 1100 and 1150 on the same motorized robot as one of the sanding or polishing tools. In one embodiment, the wiping systems 1100 and 1150 are aligned with the grinding tool, for example, adjacent to a tool on a track system, so that the wiping system can be moved to the appropriate position without significant movement of the motorized arm. In another embodiment, the wiping system is adjacent to the grinding tool, but the motorized arm must move linearly to position the wiping system appropriately on the sanded or polished area. In some embodiments, the wiping system may share a force control unit with the grinding tool. In some embodiments, the wiping system may share a motion control system with the grinding tool.

[0104] As mentioned above, in some embodiments, the fluid removal system is an active fluid removal system, such as a vacuum. However, it can be seen that when a vacuum is applied, the water in the slurry is easily removed, leaving a debris film that adheres well to the paint surface. Once the debris film is removed, it can be removed; however, nothing should be used to remove debris that could cause surface scratching. Conversely, if a vacuum is provided through a bristled surface, where the bristles pose a lower risk of scratching the paint surface, the slurry debris can be easily removed. Figures 12A to 12D A view of a vacuum attachment that can be used according to the embodiments described herein is shown. Figure 12A A side view of a brush 1200 with a vacuum attachment side 1202 and a surface contact side 1204 of a contact surface 1210 is shown. Brush bristles 1208 extend 1206 from a backing. As the brush 1200 moves across the surface 1210, the bristles 1208 remove debris adhering to the surface 1210.

[0105] Figure 12B A bottom view of the brush 1200 is shown, illustrating multiple vacuum holes 1220 through which a vacuum can be drawn.

[0106] Figure 12CA side view of brush 1250 is shown, in which a plurality of bristles 1260 and vacuum holes 1270 extend through brush 1250. The bristles 1260 are closer together than the bristles 1208. In some embodiments, the bristles 1260, 1208 are made of a material that allows them to flex, bend, or compress in response to force so that the surface is not scratched. Silicone, compliant polymers or plastics, hair, or another suitable material may be used for the bristles 1208, 1260.

[0107] A wiping system for a robotic repair unit is proposed, comprising a motorized robotic arm, a connection mechanism coupled to the motorized robotic arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The motorized robotic arm, powered by the motor, moves the wiping medium. The motorized robotic arm is configured to move the wiping medium toward or away from a work surface. The motorized arm is configured to press the wiping medium toward the work surface during the wiping operation. The wiping medium is driven by the wiping motor to press against the surface during the wiping operation.

[0108] The system can be implemented such that each of the plurality of features has a feature height and a feature thickness, wherein the feature height is greater than the thickness of the base layer.

[0109] The system can be implemented such that the height of the feature is at least twice the thickness of the feature.

[0110] The system can be implemented such that the height of the feature is less than ten times the thickness of the feature.

[0111] The system can be implemented such that the wiping medium comprises microfibers.

[0112] The system can be implemented such that the wiping medium is cord fabric microfiber.

[0113] The system can be implemented such that it includes a compliance layer between the wiping medium and the motorized robotic arm.

[0114] The system can be implemented such that the wiping motor causes the wiping medium to move in an oscillating or vibrating motion.

[0115] The system can be implemented such that the wiping motor is separated from the motor.

[0116] The system can be configured such that the wiping motor drives the wiping medium at a first speed during the wiping operation, and rotates the wiping medium at a second speed as it moves away from or toward the work surface. The second speed is higher than the first speed.

[0117] The system can be implemented such that the connecting mechanism includes a hook and loop system.

[0118] The system can be implemented such that it includes a force control unit.

[0119] The system can be implemented such that the wiping motor moves the wiping medium in a rotational motion.

[0120] The system can be implemented such that the wiping motor moves the wiping medium in an orbital motion.

[0121] The system can be implemented such that the wiping motor causes the wiping medium to move in a random orbital motion.

[0122] The system can be implemented such that the wiping motor is an electric motor.

[0123] The system can be implemented such that the wiping motor is a pneumatic motor.

[0124] The system can be implemented such that the wiping medium remains unsaturated after 10 sanding operations.

[0125] The system can be implemented such that the wiping medium remains unsaturated after 50 sanding operations.

[0126] The system can be implemented such that the wiping medium remains unsaturated after 200 sanding operations.

[0127] The system can be implemented such that the wiping medium remains unsaturated after 1000 sanding operations.

[0128] The system can be implemented such that the wiping medium removes 75% of the slurry after 50 sanding operations.

[0129] The system can be implemented such that the wiping medium removes 85% of the sludge after 100 sanding operations.

[0130] A wiping system for a robotic repair unit is proposed, comprising a motorized robotic arm, a connection mechanism coupled to the motorized robotic arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The motorized robotic arm, powered by the motor, moves the wiping medium. Each of the plurality of features has a feature height and a feature thickness. The feature height is greater than the thickness of the base layer. The feature height is at least twice the feature thickness, or the feature height is less than ten times the feature thickness.

[0131] A wiping system for a robotic repair unit is proposed. The wiping system includes a motorized robotic arm, a connection mechanism coupled to the motorized robotic arm, a compliant layer located between a wiping medium and the motorized robotic arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The motorized robotic arm, powered by the motor, moves the wiping medium.

[0132] A robotic paint repair system is proposed, comprising: a force control unit; a first tool system including a first end effector coupled to a first tool configured to contact a workpiece; a second tool system including a second end effector coupled to a second tool configured to contact the workpiece; and a fluid removal tool including a wiping medium, the fluid removal tool being coupled to a motorized robotic arm. The fluid removal tool is configured to remove fluid from the workpiece. In a first state, the first tool is in a position contacting and preparing the object surface; in a second state, the second tool is in a position contacting and preparing the workpiece; and in a third state, the fluid removal tool is in a position contacting the workpiece. The motorized robotic arm is configured to move the wiping medium toward or away from the work surface. The motorized arm is configured to press the wiping medium toward the work surface during a wiping operation. The wiping medium is driven by a wiping motor to abut against the surface during the wiping operation.

[0133] The system can be implemented such that the first tool and the second tool are mounted onto a single robotic repair unit.

[0134] The system can be implemented such that the first tool and the fluid removal tool are mounted onto a single robotic repair unit.

[0135] The system can be implemented such that the first tool and the second tool are positioned on the motorized robotic arm at least 90 degrees apart.

[0136] The system can be implemented such that the fluid removal tool is mounted perpendicular to the first tool and the second tool.

[0137] The system can be implemented such that the wiping medium comprises an absorbent material.

[0138] The system can be implemented such that the fluid removal tool includes a vacuum.

[0139] The system can be implemented such that the fluid removal tool includes an air knife.

[0140] The system can be implemented such that the wiping medium comprises microfibers.

[0141] The system can be implemented such that the wiping medium comprises corduroy fabric microfibers.

[0142] The system can be implemented such that the wiping medium has an attachment diameter at its attachment to the robotic repair unit, and wherein a plurality of absorbent units extend away from the axis defined by the attachment diameter, and wherein each absorbent unit comprises a plurality of microfiber strands.

[0143] The system can be implemented such that the microfibers are at least 300 gpsm.

[0144] The system can be implemented such that the wiping motor causes the wiping medium to move in an oscillating or vibrating motion.

[0145] The system can be implemented such that the fluid removal tool includes a compliant device.

[0146] The system can be implemented such that the compliant device is a compliant material.

[0147] The system can be configured such that the wiping motor drives the wiping medium at a first speed during the wiping operation, and causes the wiping medium to rotate at a second speed, wherein the second speed is higher than the first speed, as the wiping medium moves away from or toward the working surface.

[0148] The system can be implemented such that after 10 sanding operations, the wiping medium removes at least 70% of the slurry from the surface.

[0149] The system can be implemented such that after 100 sanding operations, the wiping medium removes at least 70% of the slurry from the surface.

[0150] The system can be implemented such that after 200 sanding operations, the wiping medium removes at least 70% of the slurry from the surface.

[0151] The system can be implemented such that the fluid removal tool is directly fastened to the first end effector.

[0152] The system can be implemented such that the fluid removal tool is connected to a force control unit.

[0153] The system can be implemented such that the first tool is connected to the force control unit.

[0154] The system can be implemented such that the fluid removal tool is fastened to the end effector system using compliant fasteners.

[0155] The system can be implemented such that the wiping medium includes a sponge.

[0156] The system can be implemented such that the wiping medium is a textile.

[0157] The system can be implemented such that the wiping medium is at an angle relative to the workpiece surface.

[0158] The system can be implemented such that the textile includes a plurality of raised portions arranged in rows, wherein a plurality of channels are formed by the arranged rows.

[0159] The system can be implemented such that the wiping medium is positioned such that the plurality of channels are at an angle relative to the wiping direction.

[0160] The system can be implemented such that the textile includes a plurality of raised portions, wherein the first row of raised portions is offset from the second row of raised portions, such that the textile has no channels.

[0161] The system can be implemented such that the textile has virtually no channels.

[0162] The system can be implemented such that the wiping medium can be removed from the robotic repair system using a connecting mechanism.

[0163] The system can be implemented such that the wiping medium is a disposable wiping medium, including the connection mechanism for connecting to the fluid removal tool. The disposable wiping medium is saturated after a single wiping operation.

[0164] The system can be implemented such that the connecting mechanism is a fastener.

[0165] The system can be implemented such that the connection mechanism is compliant.

[0166] The system can be implemented such that the connecting mechanism includes a hook and loop system.

[0167] The system can be implemented such that the fluid removal tool includes a roller-to-roll system. The wiping medium unfolds from the first roller and rolls onto the second roller.

[0168] The system can be implemented such that the wiping medium is a strip extending on a first roller and a second roller, wherein the first roller and the second roller are spaced apart.

[0169] The system can be implemented such that the wiping medium is indexed after each use, such that a first portion of the wiping medium unfolds from the first roller and a second portion rolls onto the second roller. The first portion has a first region, the second portion has a second region, and the first region and the second region are approximately similar in size.

[0170] The system can be implemented such that the wiping medium is under tension.

[0171] The system can be implemented such that tension is applied by a tension bar.

[0172] The system can be implemented such that the tension bar is compliant.

[0173] The system can be implemented such that the roller-to-roll system includes a debris removal mechanism for removing debris from the second portion.

[0174] The system can be implemented such that the roller-to-roll system includes a debris removal mechanism for removing debris from the second portion.

[0175] The system can be implemented such that it also includes an airflow directed at the second portion.

[0176] The system can be implemented such that the debris removal mechanism includes pins, scrapers, or impact tools.

[0177] The system can be implemented such that the fluid removal tool is secured in place to allow access to the workpiece surface when the system is switched from the first tool to the second tool.

[0178] The system may further include a sensor configured to detect the operating status of the defect repair system; and a control circuit for receiving signals from the sensor and processing the signals to generate status information of the defect repair system.

[0179] The system can be implemented such that the defect repair system is mounted on a mobile robotic arm.

[0180] The system can be implemented such that the compliant fastener includes a pneumatic cylinder, a linear servo driver, an air force controller, a hydraulic cylinder, a rubber pad, or a spring.

[0181] A robotic paint repair system is proposed, comprising: a force control unit; a first tool system including a first end effector coupled to a first tool configured to contact a workpiece; a second tool system including a second end effector coupled to a second tool configured to contact the workpiece; and a fluid removal tool configured to remove fluid from the workpiece. The fluid removal tool is directly fastened to the first end effector. In a first state, the first tool is in a position contacting and preparing the object surface; in a second state, the second tool is in a position contacting and preparing the workpiece; and in a third state, the fluid removal tool is in a position contacting the workpiece.

[0182] A robotic paint repair system is proposed, comprising: a force control unit; a first tool system including a first end effector coupled to a first tool configured to contact a workpiece; a second tool system including a second end effector coupled to a second tool configured to contact the workpiece; and a fluid removal tool configured to remove fluid from the workpiece, wherein the fluid removal tool is coupled to the force control unit. In a first state, the first tool is in a position contacting and preparing the object surface; in a second state, the second tool is in a position contacting and preparing the workpiece; and in a third state, the fluid removal tool is in a position contacting the workpiece.

[0183] A method for repairing a workpiece is proposed, the method comprising contacting the workpiece with a first tool. The first tool is attached to a first end effector, which is aligned to process the workpiece surface. The first end effector is coupled to a first force control unit mounted to the end-arm portion of a robotic repair unit, wherein the first tool is a grinding tool. The method further comprises removing fluid from the workpiece using a fluid removal tool coupled to the robotic repair unit. The fluid removal tool is a wiping medium, and wherein the wiping medium comprises an absorbent material. The method further comprises contacting the workpiece with a second tool. The second tool is a second grinding tool.

[0184] The method can be implemented such that the fluid removal tool is actuated during movement of the arm end portion of the robotic repair unit.

[0185] The method can be implemented such that the first tool is a sanding tool.

[0186] The method can be implemented such that the second tool is a polishing tool.

[0187] The method can be implemented such that both the first tool and the second tool are mounted to the end portion of the arm of the robotic repair unit, and the first tool and the second tool are mounted at least 90 degrees apart.

[0188] The method can be implemented such that the fluid removal tool is mounted perpendicular to one of the first tool and the second tool.

[0189] The method can be implemented such that the wiping medium includes a backing and a plurality of protrusions extending from the backing.

[0190] The method can be implemented such that each of the plurality of protrusions includes strands of fiber.

[0191] The method can be implemented such that the absorbent material is microfiber.

[0192] The method can be implemented such that the absorbent material is corduroy fabric microfiber.

[0193] The method can be implemented such that the microfibers have a density of at least 200 g / sqm.

[0194] The method can be implemented such that the microfibers have a density of at least 300 g / sqm.

[0195] The method can be implemented such that the microfibers have a density of at least 400 g / sqm.

[0196] The method can be implemented such that the microfibers have a density of at least 500 g / sqm.

[0197] The method can be implemented such that the fluid removal tool is a vacuum.

[0198] The method can be implemented such that it further includes a debris removal attachment.

[0199] The method can be implemented such that the debris removal attachment includes bristles.

[0200] The method can be implemented such that the fluid removal tool is an air knife.

[0201] The method can be implemented by connecting the fluid removal tool to a fluid removal force control unit.

[0202] The method can be implemented such that the fluid removal tool is connected to a motion controller.

[0203] The method can be implemented such that the motion controller moves the fluid removal tool closer to or further away from the workpiece.

[0204] The method can be implemented by causing the motion controller to rotate the fluid removal tool.

[0205] The method can be implemented such that the wiping medium is a sponge.

[0206] The method can be implemented such that the wiping medium is a textile with multiple channels.

[0207] The method can be implemented such that the wiping medium includes a plurality of channels defined by protrusions, and the wiping medium is angled relative to the workpiece surface such that the channels are angled relative to the wiping direction.

[0208] The method can be implemented by offsetting the first channel from the second channel.

[0209] The method can be implemented such that the wiping medium is a cloth without protrusions.

[0210] The method can be implemented such that the wiping medium is removable.

[0211] The method can be implemented such that the wiping medium is a disposable wiping medium, including a connection mechanism for connecting to the fluid removal tool.

[0212] The method can be implemented such that the connecting mechanism is a fastener.

[0213] The method can be implemented such that the connecting mechanism is compliant.

[0214] The method can be implemented such that the connecting mechanism includes a hook and loop system.

[0215] The method can be implemented such that the fluid removal tool includes a roller-to-roll system. The wiping medium is unrolled from the first roller and rolled onto the second roller.

[0216] The method can be implemented such that removing fluid from the workpiece includes unrolling a first portion of the wiping medium from a first roller and rolling a second portion of the wiping medium onto a second roller. The first portion has a first region, the second portion has a second region, and wherein the first region and the second region are substantially similar.

[0217] The method can be implemented such that it further includes removing debris from the second portion.

[0218] The method can be implemented such that removing fluid from the workpiece includes the fluid removal tool passively contacting the workpiece surface when the arm end assembly transitions from a first state including contact between the first tool and the workpiece and a second state including contact between the second tool and the workpiece.

[0219] The method can be implemented such that removing fluid from the workpiece includes, when the arm end assembly transitions from a first state including contact between the first tool and the workpiece and a second state including contact between the second tool and the workpiece, the fluid removal tool semi-passively contacts the workpiece surface, such that a motion controller coupled to the arm end assembly extends the fluid removal tool into the workpiece contact position.

[0220] The method can be implemented such that the first tool is fastened to the end-arm robot assembly.

[0221] The method can be implemented such that the workpiece is a vehicle.

[0222] The method can be implemented such that the vehicle is an automobile.

[0223] A fluid removal system mounted on a motorized robotic system is proposed. The fluid removal system includes a first roller mounted to the motorized robotic system, a second roller spaced apart from the first roller, a tension bar, and a wiping material configured to roll off the first roller, over the tension bar, and onto the second roller. The tension bar is positioned such that a portion of the wiping material contacting the tension bar on a first side contacts the workpiece on a second side.

[0224] The system can be implemented such that the wiping medium is a textile with multiple channels.

[0225] The system can be implemented such that the textile is a fabric.

[0226] The system can be implemented such that the wiping medium is at an angle relative to the workpiece surface, causing the channel to be misaligned with the wiping direction.

[0227] The system can be implemented such that misalignment includes the channel being at an angle relative to the wiping direction.

[0228] The system can be implemented such that the first channel is offset from the second channel.

[0229] The system can be implemented such that the first channel and the second channel are interleaved.

[0230] The system can be implemented such that the wiping medium is a cloth without any protrusions.

[0231] The system can be implemented such that the wiping medium has no obvious channels.

[0232] The system can be implemented such that the fluid removal system includes a motion controller.

[0233] The system can be implemented such that the motion controller moves the tension bar.

[0234] The system can be implemented such that the motion controller controls the tilt angle, pitch angle, and yaw angle of the tension bar.

[0235] A mobile robotic repair system is proposed, comprising a force control unit mounted to the system and a first tool coupled to a first end effector. The first tool is configured to contact a workpiece. The first tool is a grinding tool. The system further includes a fluid removal system comprising a wiping material and a repair tool that removes some fluid or dried debris from the wiping material. The fluid removal tool is configured to remove fluid or debris from an area of ​​the work surface, and the fluid removal system is mounted to the mobile robotic repair system.

[0236] The system can be implemented such that the fluid removal system includes a fluid removal tool that contacts the working surface.

[0237] The system can be implemented such that the fluid removal system includes an air delivery device for supplying air to the area.

[0238] The system can be implemented such that the removal system includes a vacuum that draws fluid from the region.

[0239] The system can be implemented such that the fluid removal tool includes the wiping material.

[0240] The system can be implemented such that the fluid removal system includes an absorbent wiping textile.

[0241] The system can be implemented such that the absorbent wiping textile is a woven fabric or a nonwoven fabric.

[0242] The system can be implemented such that the fluid removal system includes a roller-to-roll system.

[0243] The system can be implemented such that the roller-to-roll system includes a first roller and a second roller. A first portion of the wiping medium is unrolled from the first roller and rolled onto the second roller.

[0244] The system can be implemented such that the wiping medium is indexed after each use, such that a first portion of the wiping medium is unrolled from the first roller and a second portion is rolled onto the second roller, wherein the first portion has a first region, the second portion has a second region, and the first region and the second region are approximately similar in size.

[0245] The system can be implemented such that the wiping medium includes a strip.

[0246] The system can be implemented such that it includes a fluid distributor that distributes fluid to the region.

[0247] The system can be implemented such that it includes a second tool coupled to a second end effector. The second tool is configured to contact the working surface.

[0248] The system can be implemented such that the first tool is a sanding tool and the second tool is a polishing tool. The fluid removal system is configured to remove fluid after the first tool contacts the area and before the second tool contacts the area.

[0249] The system can be implemented such that the first end effector is connected to the force control unit.

[0250] The system can be implemented such that the second end effector is connected to the force control unit.

[0251] The system can be implemented such that the fluid removal tool is connected to the force control unit.

[0252] The system can be implemented such that the region includes a defect, and the robotic repair system is configured to repair the defect.

[0253] The system can be implemented such that the first tool is a sanding tool for sanding the defect.

[0254] The system can be implemented such that the first tool is a polishing tool for polishing the area.

Claims

1. A wiping system for a robotic repair unit, comprising: A mobile robotic arm, the mobile robotic arm having a motor; A connecting mechanism, which is connected to the motorized robotic arm; A wiping medium, coupled to the connecting mechanism, wherein the wiping medium is used to remove fluid prior to surface polishing, and comprises: basal layer; and Multiple feature portions extending from the base layer; and The motor-powered robotic arm moves the wiping medium. The motorized robotic arm is configured to move the wiping medium toward or away from the work surface, the motorized robotic arm is configured to press the wiping medium toward the work surface during the wiping operation, and the wiping medium is driven by a wiping motor to press against the surface during the wiping operation. The motorized robotic arm applies a force against the working surface to the wiping medium, causing the wiping medium to move at a lateral velocity and rotate at a rotational velocity, wherein the force, the lateral velocity, and the rotational velocity cause the wiping medium to approach a steady-state operation of water absorption during the wiping cycle.

2. The wiping system for a robot repair unit according to claim 1, wherein each of the plurality of features has a feature height and a feature thickness, and wherein the feature height is greater than the thickness of the base layer.

3. The wiping system for a robotic repair unit according to claim 1, wherein the wiping medium comprises microfibers.

4. The wiping system for a robotic repair unit according to claim 1, wherein the wiping motor causes the wiping medium to move in an oscillating or vibrating motion.

5. The wiping system for a robot repair unit according to claim 1, wherein the wiping motor is separate from the motor.

6. The wiping system for a robotic repair unit according to claim 1, wherein the wiping motor drives the wiping medium at a first speed during the wiping operation, and causes the wiping medium to rotate at a second speed as the wiping medium moves away from or toward the working surface.

7. The wiping system for a robotic repair unit according to claim 6, wherein the second speed is higher than the first speed.

8. The wiping system for a robot repair unit according to claim 1, wherein the connecting mechanism includes a hook and loop system.

9. The wiping system for a robot repair unit according to claim 1 further includes a force control unit.

10. The wiping system for a robotic repair unit according to claim 6, wherein the wiping motor moves the wiping medium in a rotational motion.

11. The wiping system for a robotic repair unit according to claim 6, wherein the wiping motor causes the wiping medium to move in an orbital motion or a random orbital motion.

12. The wiping system for a robotic repair unit according to claim 1, wherein the wiping medium remains unsaturated after 10 sanding operations.

13. The wiping system for a robotic repair unit according to any one of claims 1 to 12, wherein the wiping medium removes 75% of the sludge after 50 sanding operations.

14. The wiping system for a robotic repair unit according to claim 1, wherein the motorized robotic arm moves the wiping medium such that the outer region of the wiping medium entrains a large portion of the fluid removed from the surface.

15. The wiping system for a robotic repair unit according to claim 14, wherein the motorized robotic arm includes a spindle coupled to the wiping medium, and wherein the spindle rotates the wiping medium when the wiping medium engages the surface.

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