Automated mobile sprayer and related methods

Abstract

Automated mobile sprayer and related methods. An automated mobile sprayer configured to spray a fluid onto a target surface includes a mobile base, a spray module supported by the mobile base, at least one path sensor, and a control module configured to: receive look-ahead data from the at least one path sensor; determine a first distance to a feature; determine a first overlap parameter based on the first distance, the first overlap parameter indicative of a first degree of overlap; control the mobile base and the spray module to spray at least one vertical swath based on the first overlap parameter; determine a second distance to the feature, the second distance shorter than the first distance; determine a second overlap parameter based on the second distance, the second overlap parameter indicative of a second degree of overlap; and control the mobile base and the spray module to spray at least one vertical swath based on the second overlap parameter for another portion of the target surface different from the portion of the target surface.

Description

[0001] This application is a divisional application of the Chinese national phase patent application with application number 202080084403.2, which was filed on June 6, 2022, after the international application PCT application with application number PCT / US2020 / 063257, international application date December 4, 2020, entitled "Automatic mobile jetter and method of using the same, jetting system".

[0002] Cross-reference to related applications

[0003] This application claims priority to U.S. Provisional Application No. 62 / 944,703, filed December 6, 2019, entitled “Active Spray Overlap Adjustment for an Automated Mobile Sprayer,” and to U.S. Provisional Application No. 62 / 962,005, filed January 16, 2020, entitled “Non-Spray Area Identification and Navigation for an Automated Mobile Sprayer,” the entire disclosure of which is incorporated herein by reference. Background Technology

[0004] This disclosure generally relates to mobile fluid spraying systems. More specifically, this disclosure relates to automated mobile painting systems.

[0005] A fluid jetting system generates atomized fluid jets and applies them to a surface. The jets are typically oriented horizontally or vertically. In a horizontal orientation, the jets sweep across the surface vertically. In a vertical orientation, the jets sweep across the surface horizontally. Thus, the jets are oriented orthogonally to the sweeping direction. Typically, the user operates the spray gun to apply fluid to the surface.

[0006] Automated painting systems are typically used to paint components such as doors and panels. Autonomous painting systems utilize a robotic arm that moves in three-dimensional space to apply paint to the component. The robotic arm is complex and requires multiple joints to provide the degrees of freedom needed to coat the component. Furthermore, because the robotic arm's base is fixed to the factory floor, the component needs to be moved to a position accessible to the robotic arm. Summary of the Invention

[0007] According to one aspect of this disclosure, an automated mobile jetter configured to spray fluid onto a target surface includes: a mobile base; a jetting module supported by the mobile base, the jetting module being movable relative to the base and the target surface along a vertical axis and configured to generate a fluid jet for application onto the target surface; at least one front sensor oriented to look ahead along the travel path of the AMS and generating look-ahead data regarding the distance to an object in the travel path; and a control module configured to receive the look-ahead data from the at least one front sensor, determine the distance to an endpoint of the target surface, and control the displacement of the AMS relative to the target surface based on the distance to the object. The control module is configured to dynamically adjust the overlap distance of the displacement of the AMS relative to the target surface such that the final orthogonal strip applied to the target surface is at the endpoint of the target surface.

[0008] According to an additional or alternative aspect of this disclosure, a method for spraying fluid onto a target surface using an automated moving injector includes: applying the sprayed fluid to the target surface using an AMS according to an along-wall routine, wherein a control module of the AMS causes the AMS to laterally shift relative to the target surface by an initial overlap distance between each strip applied to the target surface; the control module determines an operating distance to an endpoint on the target surface; the control module compares the operating distance with a threshold; and the control module initiates a dynamic overlap routine based on the comparison indicating that the operating distance is equal to or less than the threshold. During the dynamic overlap routine, the control module is configured to dynamically adjust the initial overlap distance to a dynamic overlap distance and laterally shift the AMS relative to the target surface by the dynamic overlap distance during the dynamic overlap routine, such that a final orthogonal spray applied to the target surface is positioned at the endpoint on the target surface.

[0009] According to another additional or alternative aspect of this disclosure, an automated mobile jetter (AMS) configured to spray fluid onto a target surface includes: a movable base having a transverse axis and a longitudinal axis; a drive system for moving the movable base; a jetting module supported by the movable base, the jetting module being movable relative to the base along a vertical axis, the jetting module including a nozzle configured to spray fluid longitudinally toward the target surface; one or more indicator sensors configured to sense a first indicator encountered by the AMS and generate first indicator data based on the sensed first indicator; and control circuitry. The control circuitry is configured to drive the AMS along the target surface via the drive system, detect non-jetting areas in the target surface based on the first indicator data, and control the jetting by the AMS relative to the non-jetting areas based on the first indicator data.

[0010] According to another additional or alternative aspect of this disclosure, a jetting system includes: at least one indicator disposed relative to a non-jetting area of ​​a target surface and an automated moving jetter (AMS) configured to jet fluid onto the target surface. The AMS includes a movable base having a transverse axis and a longitudinal axis; a drive system for moving the movable base; a jetting module supported by the movable base, the jetting module being movable relative to the base along a vertical axis, the jetting module including a nozzle configured to jet fluid longitudinally toward the target surface; an indicator sensor configured to sense at least one indicator and generate indicator data regarding the at least one indicator; and control circuitry. The control circuitry is configured to drive the AMS along the target surface via the drive system, detect non-jetting areas in the target surface based on the indicator data, and, based on the indicator data, control the jetting by the AMS such that the AMS does not apply fluid jetting to the non-jetting areas.

[0011] According to yet another additional or alternative aspect of this disclosure, a method includes: laterally displacing an automated moving injector (AMS) relative to a target surface in a first lateral direction; injecting fluid from the injector module of the AMS onto the target surface as the injector module of the AMS is displaced relative to the target surface; sensing an indicator located near a non-injection area on the target surface by an indicator sensor of the AMS; and stopping the injection by a control module of the AMS based on the indicator sensing by the indicator sensor. Attached Figure Description

[0012] Figure 1A This is an isometric view of an automated mobile spray system.

[0013] Figure 1B This is a side view of an automated mobile injector.

[0014] Figure 1C This is a top-view schematic diagram of an automated mobile injector.

[0015] Figure 1D This is a schematic diagram of a vertical DC strip.

[0016] Figure 2A This is a top-view schematic diagram of an automated mobile injector.

[0017] Figure 2B This is a schematic diagram of the spray area, showing the non-spray area and indicators.

[0018] Figure 3 This is an isometric view of another automated mobile injector.

[0019] Figure 4 This is a flowchart illustrating an automated mobile spraying method.

[0020] Figure 5This is a flowchart illustrating the overlap adjustment method.

[0021] Figure 6 This is a flowchart illustrating an automated mobile spraying method. Detailed Implementation

[0022] Figure 1A This is an isometric view of the automated mobile spraying system 10. Figure 1B This is a schematic side view of the Automated Mobile Injector (AMS) 12. Figure 1C This is a top view of AMS 12; Figure 1D This is a schematic diagram of a vertical DC strip. Figures 1A to 1D These will be discussed together. The automated mobile injection system 10 includes an AMS 12 and a fluid supply source 14, as well as an indicator 54. The AMS 12 includes an injection module 16, a base 18, a support 20, a sensor 22, a control module 24, wheels 26, a wheel drive 28, an applicator drive 30, and a user interface 32. The injection module 16 includes an injection body 34 and a nozzle 36. The sensor 22 includes a distance sensor 38 and an indicator sensor 40. The distance sensor 38 includes a wall sensor 38a and a path sensor 38b. The control module 24 includes a memory 42 and a control circuit 44. The fluid supply source 14 includes a reservoir 46, a pump 48, and a supply hose 50. The AMS 12 includes a longitudinal axis XX, a transverse axis YY, and a vertical axis ZZ defined relative to the AMS 12.

[0023] AMS 12 is a moving vehicle configured to apply fluids, such as paint, primer, varnish, water, oil, colorant, topcoat, coating, and solvent, to a target surface, such as surface 54. Among other options, the example surface can be an internal surface (such as an interior wall) or an external surface (such as a building). In the example shown, AMS 12 is a moving ground vehicle.

[0024] The base 18 supports the various components of the AMS 12. The base 18 can be made of any desired material to house and / or support the various components of the AMS 12. For example, the base 18 can be made of metal and / or composite materials. In some examples, the base 18 is weighted to prevent the AMS 12 from tilting during operation. Wheels 26 are mounted on the base 18 and provide prime mover power to the base 18. The wheels 26 are oriented parallel to the sprayed surface 52 to drive the AMS 12. A wheel drive unit 28 is disposed in the base 18 and operatively connected to the wheels 26. As shown, each wheel 26 is associated with a separate wheel motor 32. Each wheel motor 32 individually controls each wheel 26 to drive the lateral movement of the AMS 12 and to turn the AMS 12. In some examples, the AMS 12 steers using a skid steering technique, while in other examples, the AMS 12 is steered by reorienting the wheels 26 to face various driving directions. The wheel drive unit 28 can be any suitable motor for driving the wheels 26, such as a DC motor, stepper motor, pneumatic motor, gas-powered motor, brushed motor, brushless motor, or any other desired motor. If the wheel drive unit 28 is pneumatic, the base 18 can support an air compressor to provide compressed air to drive the wheel drive unit 28. Although the AMS 12 is described as including wheels 26, it should be understood that the AMS 12 can include any desired form of kinetic force. For example, the AMS 12 can include tracks or a combination of wheels and tracks, etc.

[0025] Support 20 extends from base 18. Spray module 16 rides on and is supported by support 20. Spray module 16 is supported by base 18 via support 20. Support 20 supports spray module 16 such that spray module 16 can move vertically along axis ZZ while being prevented from moving relative to support 20 along axis XX or axis YY. In one example, support 20 includes a recess receiving a protrusion extending from spray module 16. It should be understood that spray module 16 can be supported within support 20 and can be translated along support 20 in any desired manner.

[0026] The applicator drive 30 is operatively associated with the injection module 16 and configured to drive the injection module 16 along axis ZZ relative to the support 20 and surface 52 to apply a fluid strip to the surface 52. In some examples, the applicator drive 30 is displaced together with the injection module 16 along axis ZZ. For example, the applicator drive 30 may include one or more motors, such as electric motors, configured to drive gears that interface with grooves formed by or within the support 20. However, it should be understood that the applicator drive 30 can be any configuration suitable for driving the injection module 16 along axis ZZ.

[0027] Nozzle 36 extends from spray body 34 toward surface 52. Spray body 34 houses other components of spray module 16, such as control valves (not shown). Nozzle 36 is configured to generate a jet of fluid for application to surface 52. It should be understood that nozzle 36 can spray in any desired configuration, such as a spray fan or spray cone, etc. It should also be understood that the desired position of nozzle 36 can include coordinate position, such as distance from surface 52, and orientation, such as nozzle 36 being orthogonal to surface 52 or at another angle relative to surface 52. In some examples, non-orthogonal spray fans provide satisfactory finish. In some examples, the spray orientation is maintained during each spray pass. The quality of the topcoat applied to surface 52 depends on several factors, such as the distance between nozzle 36 and surface 52, the desired spray fan width, the applied coating thickness, fluid type, spray pressure, and orifice size in nozzle 36, among others.

[0028] In some examples, nozzle 36 can be positioned in multiple locations to change the orientation of the jet fan. For example, nozzle 36 can be vertically oriented such that the jet fan extends along the vertical axis ZZ. In such an example, jet module 16 can remain stationary on the vertical axis ZZ, and AMS 12 can translate along axis YY and relative to surface 52 to apply a horizontal fluid strip. Nozzle 36 can be positioned horizontally oriented such that the jet fan extends along the transverse axis YY. In such an example, AMS 12 remains stationary on axis YY, and jet module 16 translates along axis ZZ to apply a vertical fluid strip to surface 52. In some examples, nozzle 36 can rotate between vertical and horizontal fan orientations.

[0029] In an example where the AMS 12 includes a control valve, the control valve controls the ejection of fluid from the nozzle 36. The control valve can be an active or passive control valve. For example, when the valve is actively controlled, the control module 24 can cause the valve to shift open to allow ejection. When the valve is actively controlled, fluid pressure causes the valve to shift open. The control valve can be communicatively connected to the control module 24 to receive commands from the control module 24. The control valve can shift between a closed position and an open position, in which fluid cannot flow to the nozzle 36, and in the open position, fluid flows to the nozzle 36 to be ejected as a jet. For example, the control valve may include a needle (not shown) extending into a seat in the nozzle 36 and an actuator (not shown) for actuating the needle. In some examples, the AMS 12 does not include a control valve, such that the nozzle 36 generates a jet fan whenever the pump 48 provides pressurized fluid. The pump 48 and / or the control valve can be operatively connected to the control module 24, such that the control module 24 controls the ejection of the AMS 12.

[0030] Control module 24 is configured to store software, implement functions, and / or process instructions. Control module 24 is configured to perform any of the functions discussed herein, including receiving output from any of the sensors mentioned herein, detecting any of the conditions or events mentioned herein, and controlling the operation of any of the components mentioned herein. Control module 24 can be configured in any suitable way for controlling the operation of components of AMS 12, collecting data, processing data, etc. For example, control module 24 can receive sensor data from sensor 22, generate drive commands, send drive commands to wheel drive unit 28 to cause movement of AMS 12, generate injection commands to cause injection module 16 to emit fluid injection, control the movement of injection module 16 along the vertical axis ZZ, and execute routines based on received data, etc.

[0031] Control module 24 can be formed from various controllers located within base 18 or elsewhere on AMS 12. It should be understood that control module 24 may include hardware, firmware, and / or stored software, and control module 24 may be wholly or partially mounted on one or more boards. Control module 24 can be of any type suitable for operation according to the techniques described herein. Although control module 24 is illustrated as a single unit, it should be understood that control module 24 may be arranged across one or more boards. In some examples, control module 24 may be implemented as multiple discrete circuit sub-components.

[0032] Control module 24 can communicate via wired and / or wireless communication, such as serial communication (e.g., RS-232, RS-485, or other serial communication), digital communication (e.g., Ethernet), WiFi communication, cellular communication, or other wired and / or wireless communication. Memory 42 is configured to store software that, when executed by control circuitry 44, causes AMS 12 and fluid supply source 14 to execute instructions and apply fluid to the surface. For example, control circuitry 44 may include one or more of a microprocessor, controller, digital signal processor (DSP), application-specific integrated circuit (ASIC), field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry.

[0033] Control module 24 can be configured to store information during operation. In some examples, memory 42 is described as a computer-readable storage medium. In some examples, the computer-readable storage medium may include a non-transitory medium. The term "non-transitory" may mean that the storage medium is not included in a carrier wave or propagating signal. In some examples, memory 42 is temporary memory, meaning that the primary purpose of memory 42 is not long-term storage. In some examples, memory 42 is described as volatile memory, meaning that memory 42 does not retain its stored contents when the power of control module 24 is turned off. In some examples, memory 42 also includes one or more computer-readable storage media. Memory 42 can be configured to store a larger amount of information than volatile memory. Memory 42 can also be configured for long-term storage of information. In some examples, memory 42 includes non-volatile storage elements.

[0034] User interface 32 can be any graphical and / or mechanical interface that enables a user to interact with control module 24. For example, user interface 32 can be a graphical user interface displayed on a display device for presenting information to and / or receiving input from the user. User interface 32 may include graphical navigation and control elements, such as graphical buttons or other graphical control elements presented on a display device. In some examples, user interface 32 includes physical navigation and control elements, such as physically activated buttons or other physical navigation and control elements. Typically, user interface 32 may include any input and / or output devices and control elements that enable a user to interact with control module 24. In some examples, user interface 32 may be integrated into AMS 12. For example, user interface 32 may be formed on housing 24 for user access. In some examples, user interface 32 may be remote from AMS 12 and communicatively connected to control module 24. User interface 32 may communicate with control module 24 via wired or wireless communication. For example, user interface 32 can be a remote computing device, such as a smartphone or tablet, that communicates with control module 24.

[0035] Sensor 22 is configured to sense walls and other structures and features relative to AMS 12. It should be understood that sensor 22 may include one or more distance sensors, position sensors, inertial sensors, proximity sensors, and / or optical sensors. For example, sensor 22 may include one or more of a proximity sensor, radar transducer, vibration echo rangefinder (including ultrasonic and / or acoustic rangefinders), laser rangefinder, magnetometer, radar, lidar, GPS receiver chip, accelerometer, gyroscope, compass, and / or camera. Sensor 22 generates sensor data for AMS 12 and provides the sensor data to control module 24. Control module 24 receives the sensor data from sensor 22 and is configured to control the movement of AMS 12 and the spraying of nozzle 36 based at least in part on the sensor data. Sensor 22 can be any suitable configuration for generating information about features in the travel path of AMS 12. For example, the individual sensors in sensor 22 can be oriented toward surface 52, can be oriented along axis YY on the travel path of AMS 12, can be oriented between these two directions, or can be set in any other orientation for generating data.

[0036] Distance sensor 38 is configured to generate distance data about objects and features relative to AMS 12. In some examples, distance sensor 38 may be oriented toward surface 52. In some examples, distance sensor 38 may be oriented to look ahead along the travel path of AMS 12. It should be understood that AMS 12 may include multiple distance sensors positioned at various orientations to generate distance data.

[0037] Wall sensor 38a is a distance sensor facing surface 52. Wall sensor 38a can provide control module 24 with positional information regarding the position and orientation of nozzle 36 relative to surface 52. In some examples, AMS 12 includes two wall sensors 38a spaced apart from nozzle 36. However, it should be understood that AMS 12 can include more than two wall sensors 38a. In some examples, multiple wall sensors 38a are equidistant from nozzle 36 on opposite sides of nozzle 36. However, it should be understood that the positions of the wall sensors 38a are known to control module 24, allowing the wall sensors 38a to be positioned on AMS 12 at any desired location suitable for generating distance data regarding the distance to surface 52. In some examples, wall sensors 38a are not equidistant from nozzle 44.

[0038] The path sensor 38b is a distance sensor oriented to look ahead from the AMS 12 to detect features in the AMS 12's path of travel. For example, the path sensor 38b can detect changes in surface 52, such as protrusions or intersections with another surface. In some examples, the AMS 12 includes multiple path sensors 38b positioned at various orientations. For example, the AMS 12 may include one or more path sensors 38b oriented to observe along axis YY in the AMS 12's path of travel; such path sensors 38b may also be referred to as front sensors. The AMS 12 may also include one or more path sensors 38b oriented to observe along the orientation between axis XX and axis YY; such path sensors 38b may be referred to as intermediate sensors. The path sensor 38b is configured to generate distance data about the distance to features the AMS 12 is approaching, such as the distance to gaps formed in surface 52 or the ends of surface 52 (e.g., where walls intersect).

[0039] Indicator sensor 40 is a sensor configured to detect the presence of indicator 54 and generate indicator data regarding the presence of indicator 54. In some examples, AMS 12 includes multiple indicator sensors 40 configured to sense various indicators 54. Indicator sensor 40 is configured to detect the presence of indicator 54 and generate a signal regarding the presence of indicator 54. Indicator sensor 40 can be positioned on AMS 12 at any desired location suitable for sensing indicator 54. For example, indicator sensor 40 can be positioned on or within base 18, can be mounted to injection module 16, or can be positioned at any other suitable location. In the example where indicator sensor 40 is mounted to injection module 16, indicator sensor 40 can travel vertically with injection module 16.

[0040] The indicator sensor 40 may include any one or more of an optical sensor and a proximity sensor, etc. In an example where the indicator sensor 40 is an optical sensor, the optical sensor may be oriented to look ahead in the travel path of the AMS 12 and / or the injection module 16. For example, the optical sensor may be mounted to the injection module 16 to travel with the injection module 16 and may be oriented to look ahead in the travel path of the injection module 16, such that the optical sensor detects the indicator 54 before the nozzle 36 reaches the indicator 54.

[0041] The indicator sensor 40 may utilize proximity sensing technologies such as passive and / or active radio frequency identification (RFID) sensing, near field communication (NFC), inductive sensing, capacitive sensing, or other proximity sensing technologies. For example, an RFID tag may be associated with one of the indicators 54 and AMS 12, such as being located on or within one of the indicators 54 and AMS 12, and an RFID reader may be associated with the other of the indicators 54 and AMS 12. Similarly, an NFC tag may be associated with one of the indicators 54 and AMS 12, such as being located on or within one of the indicators 54 and AMS 12, and an NFC reader may be associated with the other of the indicators 54 and AMS 12. A first inductive or capacitive sensing element may be associated with one of the indicators 54 and AMS 12, such as being located on or within one of the indicators 54 and AMS 12, and a second inductive or capacitive sensing element may be associated with the other of the indicators 54 and AMS 12.

[0042] Indicator 54 is positioned relative to non-spraying area 56. When preparing a location for spraying, the user can place indicator 54 relative to non-spraying area 56. Non-spraying area 56 refers to those areas on target surface 52 where fluid is not intended to be applied. For example, non-spraying area 56 may include gaps, such as doorways and windows, etc. Indicator 54 is located near non-spraying area 56 to indicate the boundary of non-spraying area 56. In some examples, indicator 54 includes circuitry configured to store information about non-spraying area 56 and / or instructions regarding spraying relative to non-spraying area 56. For example, indicator 54 may provide instructions that AMS 12 should stop at indicator 54 and wait for further instructions from the user, that AMS 12 should move laterally across target surface 52 without spraying until encountering another indicator 54, that AMS 12 should apply fluid to certain portions of target surface 52 but not others (such as above and below a window, where information includes the window's size and location), etc.

[0043] Indicator 54 can be a pad, a disc, or other object placed on the ground. In the example shown, indicator 54 is placed on the ground adjacent to non-spraying area 56. The pad may include markers, such as proximity sensor components embedded within the pad. In such an example, the pad is a support member 58 component supporting sensor component 60, which may include circuitry. For example, RFID components such as RFID tags or RFID readers, NFC components such as NFC tags or NFC readers, or inductive sensing components may be embedded in the pad as sensor component 60. In some examples, indicator 54 may be formed of a material configured to be sensed by indicator sensor 40. For example, indicator 54 may be formed of or include metal components configured to be sensed by a magnetic sensor forming indicator sensor 40, such as when indicator 54 is a metal plate or includes metal elements. Indicator sensor 40 is configured to sense markers and generate indicator data based on that detection. In some examples, AMS 12 is configured to sense indicator 54 while traveling over it.

[0044] Fluid supply source 14 stores fluid and supplies fluid to AMS 12 for application to surface 52. Although fluid supply source 14 is shown located outside AMS 12, it should be understood that in some examples, fluid supply source 14 may be on-board of AMS 12. For example, reservoir 46 and pump 48 may be located within housing 24 of AMS 12.

[0045] Reservoir 46 is configured to store a large volume of fluid. Pump 48 is disposed on reservoir 46 and configured to draw fluid from reservoir 46, pressurize the fluid, and drive the fluid downstream to nozzle 36 of AMS 12. Reservoir 46 is any suitable vessel for storing a fluid supply prior to application. For example, reservoir 46 may be a barrel. Pump 48 may be a piston pump, diaphragm pump, peristaltic pump, or any other suitable pump for driving fluid under pressure to nozzle 36 of AMS 12. In some examples, pump 48 generates sufficient pressure to atomize the fluid at nozzle 36 and create a jet fan. In other examples, AMS 12 may include a secondary pump configured to generate the high pressure required to atomize the fluid (approximately 3.45–27.58 MPa (approximately 500–4000 psi)). Thus, in some examples, pump 48 may be a low-pressure pump used to drive the fluid to an onboard pump, which then generates the desired jet pressure. Supply hose 50 extends from pump 48 to AMS 12 to provide pressurized fluid to nozzle 36 of AMS 12 for application to surface 52. In some examples, supply hose 50 extends from pump 48 to injection body 34.

[0046] During operation, the AMS 12 generates and applies jets of fluid (such as paint) to a surface, which may be difficult for a person to easily access and / or effectively apply the fluid to. In some examples, the AMS 12 uses multiple parallel grating paths to apply fluid to the surface. Grid traversal occurs when a first horizontal or vertical strip is applied to the surface, and a second horizontal or vertical strip is applied directly near and / or overlaps with the first strip. Any number of strips can be applied until the surface 52 is sufficiently coated. In some embodiments, the pump 48 and / or reservoir 46 are entirely supported on the AMS 12. For example, one or both of the pump 48 and reservoir 46 may be supported on the base 18 as the AMS 12 propels itself.

[0047] Pump 48 is activated either automatically by control module 24 or by the user, and draws fluid from reservoir 46 and drives the fluid downstream to nozzle 36 via supply hose 50. Nozzle 36 produces a jet and moves laterally and / or vertically across surface 52 to apply fluid to surface 52. Control module 24 vertically moves nozzle 36 by shifting jet module 16 along axis ZZ, thereby causing relative vertical movement of nozzle 36. Control module 24 causes relative horizontal movement of nozzle 36 by driving wheel 26 to shift AMS 12 and nozzle 36 laterally along axis YY. Control module 24 controls the positioning of AMS 12 during jetting based on distance data generated by sensor 22. For example, control module 24 may control the distance between AMS 12 and surface 52 based on distance data generated by wall sensor 38a.

[0048] AMS 12 initially operates according to a wall-following routine. During the wall-following routine, AMS 12 is driven along the axis YY, maintaining a distance D1 between nozzle 36 and surface 52. Control module 24 can cause AMS 12 to operate in a wall-following mode and / or an overlap adjustment mode during the wall-following routine. During the wall-following routine, control module 24 controls the movement of AMS 12 along the axis YY, such that AMS 12 is positioned relative to surface 52 at a desired orientation for spraying. For example, control module 24 can control AMS 12 such that the axis YY is substantially parallel to surface 52 during spraying. Given that each of the multiple wall sensors 38a indicates the same distance to surface 52, control module 24 determines that nozzle 36 is orthogonal to surface 52 and further knows the distance D1 spaced between nozzle 36 and surface 52. If one of the wall sensors 38a indicates a different distance than the other wall sensor 38a, the control module 24 can determine that the nozzle 36 is tilted away from the surface 52 and toward the wall sensor 38a that indicates a greater distance from the surface 52 than the other wall sensor 38a.

[0049] The control module 24 can perform correction actions based on information provided by the wall sensors 38a to reorient the AMS 12 to the desired spray position. For example, the control module 24 can command one or more wheel drive units 28 to rotate the wheels 26 to reorient the AMS 12 to the desired spray position. For example, if one wall sensor 38a indicates a greater distance to the surface 52 than the other wall sensor 38a, the control module 24 can adjust the orientation of the AMS 12 until both wall sensors 38a indicate the same distance, and the indicated distance is the desired distance.

[0050] During the spraying of both horizontal and vertical stripes, the control module 24 can control the spraying based on the grid stripes. Figure 1D An example is shown where AMS 12 applies a vertical DC strip A defined by vertical lines A1 and A2, and a vertical DC strip B defined by vertical lines B1 and B2. Lines A1 and A2 represent the lateral boundaries of the first spray fan applying strip A to surface 52, while lines B1 and B2 represent the lateral boundaries of the second spray fan applying strip B to surface 52. As shown, the first and second spray fans are adjacent and overlap. Vertical strips A and B overlap with an overlap parameter C1. When operating in wall-side mode, the overlap parameter can be preset in control module 24 and / or provided by the user to control the amount of overlap between adjacent strips. The overlap parameter C1 can be a programmable distance or a percentage of overlap between strips. For example, a 50% overlap parameter means that half of each strip is applied over the previous strip, such that each portion of surface 52 is coated twice.

[0051] An example of an injection event in which the AMS 12 applies a vertical stripe of fluid will be discussed further herein. When a vertical stripe of fluid is applied, the nozzle 36 generates a horizontal jet fan. The horizontal jet fan extends laterally relative to the surface 52 along the YY axis. The injection routine can be initiated by the control module 24 and / or the user. When the injection routine begins, the control module 24 positions the AMS 12 at the desired starting position, thereby positioning the injection module 16 and the nozzle 36 at the desired starting position. The control module 24 controls the movement of the AMS 12 via the wheel drive 28. The AMS 12 moves to position the nozzle 36 relative to the surface 52 at a desired distance, position, and orientation.

[0052] Pump 48 is activated by control module 24 or by a user to drive fluid downstream to nozzle 36. In some examples, control module 24 may provide a start-injection command to the control valve to initiate injection. The start-injection command causes the control valve to open the flow path through nozzle 36, such as by opening the flow path via an actuation needle. Fluid flows through the flow path and is ejected from nozzle 36 as an atomized jet. In some examples, the control valve is passively actuated to the open state when pump 48 generates sufficient pressure. To stop injection, control module 24 may deactivate the pump and / or shift the control valve to the closed position, etc.

[0053] Control module 24 controls the spraying to apply a smooth and uniform finish to the surface. In some examples, control module 24 controls the spraying such that nozzle 36 moves relative to surface 52 before fluid is ejected from nozzle 36. Initiating spraying as nozzle 36 moves reduces, or in some examples eliminates, undesirable effects caused by splashing, which most commonly occurs at the start and end of spraying. Since nozzle 36 is already in motion, any undesirable spray pattern is uniformly distributed on surface 52 and can be corrected by subsequent fluid application. Control module 24 can implement a delay between activating wheel drive 28 or applicator drive 30 and opening control valve 46 to delay spraying until nozzle 36 moves.

[0054] Control module 24 generates a jetting command and provides it to the injector drive unit 30 to initiate the vertical movement of jetting module 16 along the vertical axis ZZ. Nozzle 36 jets fluid, and jetting module 16 applies a first vertical straight-line jet to surface 52. Control module 24 can initially operate AMS 12 in wall-following mode.

[0055] After the first vertical strip is applied, control module 24 activates wheel drive 28 to cause AMS 12 to shift laterally along axis YY and relative to surface 52 according to initial overlap parameter C1 to apply second and additional vertical strips. The initial overlap parameter C1 can be set by the user or determined by control module 24, such as at the start of the spray event. For example, if each strip is 12 inches (in.) (approximately 30.48 centimeters (cm)) wide, then a 50% overlap parameter provides an overlap distance of 6 in. (15.24 cm). In some examples, the overlap parameter is the overlap distance, i.e., 6 in. in the example discussed. Control module 24 causes AMS 12 to shift according to the initial overlap parameter between each strip application. AMS 12 continues to apply strips based on the initial overlap parameter C1 until control module 24 enters overlap adjustment mode.

[0056] Path sensor 38b generates data about the distance to features in surface 52. These features can be windows, doorways, wall transitions, or other features in surface 52. Control module 24 can cause AMS 12 to apply fluid to surface 52 until it reaches a feature. It should be understood that applying fluid until it reaches a feature can include stopping at a endpoint EP associated with the feature but not at the feature itself, which endpoint EP can be located at or spaced from the feature. For example, endpoint EP can be located at a point on surface 52 where a wall routine ends and another routine, such as a wall transition routine, is executed. In such an example, endpoint EP can be spaced sufficiently from adjacent walls to give AMS 12 operating space relative to the transition and to orient itself on the adjacent wall to spray onto the adjacent wall. Control module 24 can determine endpoint EP by applying an interval factor to distance D2, which can be the distance between AMS 12 and the wall at the start of another routine. For example, control module 24 can determine the distance to endpoint EP by subtracting the interval factor from distance D2.

[0057] In the wall-following routine, drive errors and sensor errors can cause the actual overlap between adjacent strips to differ from the initial overlap parameter C1. For example, wheel 26 may shift AMS 12 by slightly less or more than the commanded drive distance, or the orientation of AMS 12 relative to surface 52 may need adjustment to provide parallelism before the strips are sprayed. As the distance from D2 to surface T decreases, the accuracy of path sensor 38b also increases. This error and / or physical composition of surface 52 as AMS 12 approaches surface T causes the traversal count to become a fractional traversal count, which is the count applied to the strips required to reach the endpoint EP of surface 52.

[0058] Control module 24 is configured to adjust the initial overlap parameter during operation. This adjustment can address inaccurate repositioning movement due to drive and / or sensor errors. In some examples, control module 24 dynamically adjusts the overlap parameter during operation. Control module 24 adjusts the overlap parameter C1 based on the remaining travel distance D2 to a feature of surface 52. Control module 24 can determine the travel distance D2 based on distance data provided by path sensor 38b. Control module 24 adjusts the initial overlap parameter such that the last positive AC strip W applied to surface 52 by AMS 12 is a complete strip. Dynamic overlap adjustment ensures that the final strip does not leave an unsprayed gap between the final strip and a feature of surface 52, while maintaining sufficient overlap between adjacent strips to provide the desired coverage. When operating in overlap adjustment mode, AMS 12 continues to travel along surface 52 while applying fluid. Thus, the wall-following routine can include both a wall-following mode and an overlap adjustment mode.

[0059] When running in overlap adjustment mode, control module 24 can control the operation of AMS 12 based on dynamic overlap routines. In this paper, the process by which the control module 24 controls the operation of AMS 12 in the overlap adjustment mode is also referred to as An overlap adjustment routine applies a complete final orthogonal stripe to the endpoint EP of surface 52 using AMS 12. Control module 24 can dynamically adjust the overlap parameters as AMS 12 approaches this feature after each application of a fluid stripe, and as AMS 12 approaches the feature. Control module 24 can initiate an overlap adjustment mode based on operating parameters and an adjustment threshold. For example, control module 24 can be configured to operate AMS 12 in overlap adjustment mode when the operating parameters reach an adjustment threshold. The adjustment threshold can be the distance to the endpoint EP or a remaining traversal count, where the remaining traversal count is a count of the remaining number of stripes reaching the endpoint EP, etc. When the adjustment threshold is reached, control module 24 can enter overlap adjustment mode and control AMS 12 according to the overlap adjustment routine. During the overlap adjustment routine, control module 24 determines dynamic overlap parameters and controls the movement of AMS 12 along axis YY and relative to surface 52 based on these dynamic overlap parameters. The dynamic overlap parameters can vary throughout the overlap adjustment routine, such that the overlap adjustment routine includes multiple dynamic overlap parameters O1-On. In this way, the dynamic overlap parameter can be dynamic and can change during operation.

[0060] During the overlap adjustment routine, control module 24 determines dynamic overlap parameters before shifting AMS 12 to apply the next strip. Control module 24 receives look-ahead data from path sensor 38b and determines the distance to the endpoint EP of surface 52 based on the look-ahead data. For example, the front sensor of path sensor 38b can generate distance data about the spacing to an interior corner or other projection, while the middle sensor of path sensor 38b can generate distance data about the spacing to an exterior corner or other gap.

[0061] Control module 24 can determine the number of strips required to reach the features of surface 52. Control module 24 can execute an overlap adjustment routine such that the final orthogonal jet relative to surface 52 is applied at the desired location relative to the features of surface 52 to prevent any gaps or uneven jetting. As AMS 12 approaches the end of the along-wall routine, the overlap adjustment routine further ensures that AMS 12 applies fluid uniformly.

[0062] In some examples, control module 24 may initiate an overlap adjustment routine based on a threshold distance. In such an example, if the distance D2 to the endpoint EP / feature is greater than the threshold distance, control module 24 may cause AMS 12 to continue operating according to the along-wall routine. Control module 24 initiates the overlap adjustment routine based on a distance D2 equal to or less than the threshold distance. The threshold distance can be any desired distance from the endpoint EP of surface 52, such as 12 in. (30.48 cm), 24 in. (60.96 cm), 36 in. (91.44 cm), 48 in. (121.92 cm), 60 in. (152.40 cm), or further from the endpoint EP, or any intermediate distance value.

[0063] In other examples, control module 24 may be configured to initiate an overlap adjustment routine based on a threshold traversal count. In such an example, if the remaining traversal count exceeds the threshold traversal count, control module 24 may cause AMS 12 to continue operating according to the wall-following routine. Control module 24 initiates the overlap adjustment routine based on a remaining traversal count equal to or less than the threshold traversal count. The threshold traversal count can be any desired number of traversals remaining to the endpoint EP of surface 52, such as three, four, five, ten, fifteen, or more remaining traversals, or any remaining intermediate traversal count.

[0064] An example of an overlap adjustment routine based on a threshold distance is discussed in more detail. In the example discussed, the jet fan is 12 inches wide, the initial overlap parameter C is 50%, the threshold distance is 36 inches, and the distance D2 is 34 in. (86.36 cm). Control module 24 receives look-ahead data from path sensor 38b and determines the distance D2 to be 34 inches based on the look-ahead data. Control module 24 compares the distance D2 with the threshold distance. The distance D2 is less than the threshold distance, so control module 24 initiates the overlap adjustment routine. Control module 24 determines the initial remaining traversal count of the number of strips required to fully cover surface 52 to reach the endpoint EP of surface 52. Using an overlap parameter C1 of 50%, an additional 6 inches of coverage width is applied to each strip. The initial remaining traversal count can be calculated by dividing the distance D2 by the overlap parameter applied to each strip width. In this example, the remaining traversal count has a traversal count value of 5.67 strips.

[0065] Control module 24 determines the state of the remaining traversal count, such as whether the remaining traversal count is an integer or a fraction. If the remaining traversal count is a fraction, control module 24 adjusts the remaining traversal count to an adjusted integer. A remaining traversal count that is an integer rather than a fraction provides the full-width final orthogonal strip W at the endpoint EP of surface 52. Figure 1DThe fractional traversal count can be adjusted up or down to the nearest integer. For example, an initial remaining traversal count of 5.67 can be adjusted to an adjusted traversal count of 5 or 6. In some examples, control module 24 is configured to adjust the traversal count to the nearest integer greater than the fractional remaining traversal count, providing an adjusted remaining traversal count of 6 in the example discussed. Adjusting to the next larger integer ensures that each portion of surface 52 receives at least two fluid applications. In some examples, control module 24 is configured to adjust the remaining traversal count to the nearest adjacent integer, providing an adjusted remaining traversal count of 6 in the example discussed. Adjusting to the nearest adjacent integer minimizes any difference between the dynamic overlap parameters and the initial overlap parameters.

[0066] Control module 24 determines the dynamic overlap parameter based on the adjusted traversal count and distance D2. The remaining distance D2 to the endpoint EP of surface 52 is divided by the adjusted traversal count 6 to determine the first dynamic overlap parameter O1, resulting in a first dynamic overlap distance O1 of 5.67 in. (14.40 cm), providing a first dynamic overlap percentage of 47.25%.

[0067] like Figure 1D As shown, the last strip applied before initiating the overlap adjustment routine is a vertical DC strip F defined by vertical lines F1 and F2. Control module 24 causes AMS 12 to be laterally shifted by a first dynamic overlap distance O1 relative to surface 52 along axis YY. AMS 12 applies a vertical strip G defined by vertical lines G1 and G2 at this position.

[0068] Control module 24 can determine the second dynamic overlap parameter O2 before shifting AMS 12 to apply the next vertical strip H. For example, if AMS 12 is actually moved 5.5 in. to apply the vertical strip G, then 28.5 in. remains to the endpoint EP of surface 52. The additional dynamic overlap parameter O2-On can be based on the first adjusted remaining traversal count determined during the overlap adjustment routine. Therefore, the second and subsequent dynamic overlap parameters can be determined by dividing the remaining distance (28.5 inches in this example) by the remaining traversal, which is the adjusted remaining traversal count minus the number of traversals completed during the overlap adjustment routine. In this example, the remaining traversal is 5. The resulting dynamic overlap parameter O2 has a second dynamic overlap distance of 5.7 in. (14.48 cm), providing a second dynamic overlap percentage of 47.5%.

[0069] In some examples, control module 24 is configured to continue applying stripes based on a first dynamic overlap parameter O1 as long as the magnitude of the inaccurate repositioning movement is less than a threshold. For example, if the threshold is 0.2 in. (0.51 cm), control module 24 can control the movement of AMS 12 to apply a vertical strip H based on the first dynamic overlap distance O1, where the difference between the actual movement and the commanded movement (0.17 in. in this example) is less than the threshold. In some examples, the threshold can be cumulative. For example, if additional inaccurate repositioning movements increase the difference to greater than the threshold, control module 24 can determine a second dynamic overlap parameter O2 and control the movement based on this second dynamic overlap parameter.

[0070] Control module 24 causes AMS 12 to laterally shift along axis YY relative to surface 52 by a second dynamic overlap parameter O2, and applies a vertical strip H defined by vertical lines H1 and H2 at that location. Although the same vertical lines are shown as H1 and F2, it should be understood that the boundaries of the vertical strips can vary relative to each other. Control module 24 continues to determine additional overlap parameters O3-On and controls the operation of AMS 12 based on these overlap parameters O3-On. AMS 12 continues to apply fluid strips according to the overlap adjustment routine. Control module 24 determines the final dynamic overlap parameter On and shifts AMS 12 from the position where the penultimate strip V defined by vertical lines V1 and V2 is applied to apply the final orthogonal strip W defined by vertical lines W1 and W2. AMS 12 shifts according to the dynamic overlap parameter On to apply the final orthogonal strip W. Vertical line W2 is aligned with the endpoint EP of surface 52. Thus, the final orthogonal strip W applied to surface 52 is applied at the endpoint EP of surface 52.

[0071] A more detailed, brief example of an overlap adjustment routine based on a threshold traversal count is discussed below. In the example discussed, the jet fan width is 12 inches, the initial overlap parameter is 50%, the threshold traversal count is 10 traversals, and the distance D2 is 58 in. (147.32 cm). Control module 24 determines the remaining traversal count required to fully cover surface 52 before reaching the endpoint EP of surface 52. Control module 24 compares the remaining traversal count with the threshold traversal count and initiates the overlap adjustment routine based on whether the remaining traversal count is less than or equal to the threshold traversal count.

[0072] In some examples, control module 24 can subtract the completed traversal count from the initial traversal count. In one example, control module 24 determines the initial traversal count based on look-ahead data from distance sensor 38 before activating any spraying on surface 52. Control module 24 can subtract the completed traversal count from this initial traversal count to determine the remaining traversal count. In some examples, a user can input a desired traversal count for surface 52, for example via user interface 32, and this desired traversal count can be the initial traversal count. Control module 24 can subtract the completed traversal count from the user-provided initial traversal count.

[0073] In some examples, control module 24 determines the remaining traverse count based on look-ahead data from distance sensor 38. Control module 24 receives look-ahead data from distance sensor 38 and can determine a distance D2 of 58 inches based on the look-ahead data. The remaining traverse count can be calculated by dividing distance D2 by the overlap parameter applied to each strip width. With an initial overlap parameter of 50%, an additional 6 inches of spray coverage is applied to each strip, providing a remaining traverse count of 9.67 traverses in the example discussed.

[0074] Control module 24 adjusts the initial overlap parameter C1 to the dynamic overlap parameter such that the remaining traversal count is an integer. The remaining traversal count being an integer, not a fraction, provides full-width final orthogonal spraying at the features of surface 52. The fractional remaining traversal count can be adjusted up or down to the nearest integer. For example, an initial remaining traversal count of 9.67 traversals can be adjusted to an adjusted remaining traversal count of 9 or 10. In some examples, control module 24 is configured to adjust the remaining traversal count to the nearest integer greater than the fractional remaining traversal count, providing an adjusted remaining traversal count of 10 in the example discussed. Adjusting to the next larger integer causes AMS 12 to apply fluid to each portion of surface 52 at least twice. In some examples, control module 24 is configured to adjust the remaining traversal count to the nearest adjacent integer, providing an adjusted remaining traversal count of 10 in the example discussed. Adjusting to the nearest adjacent integer minimizes any difference between the dynamic overlap parameter and the initial overlap parameter.

[0075] Control module 24 determines dynamic overlap parameters based on the adjusted traversal count and distance D2. The remaining distance D2 to the endpoint EP of surface 52 is divided by the adjusted traversal count 10 to determine the first dynamic overlap parameter O1, resulting in a first dynamic overlap distance of 5.8 in. (14.73 cm), providing a first dynamic overlap percentage of 48.33%.

[0076] like Figure 1DAs shown, the last strip applied before initiating the overlap adjustment routine is a vertical DC strip F defined by vertical lines F1 and F2. Control module 24 causes AMS 12 to laterally shift the first dynamic overlap parameter O1 relative to surface 52 along axis YY. AMS 12 applies a vertical strip G defined by vertical lines G1 and G2 at this position.

[0077] Control module 24 continues to determine additional dynamic overlap distances O2-On and controls the operation of AMS 12 based on these dynamic overlap distances O2-On. Control module 24 determines the final dynamic overlap parameter On and shifts AMS 12 from the position where the penultimate strip V, defined by vertical lines V1 and V2, is applied to apply the final orthogonal strip W, defined by vertical lines W1 and W2. AMS 12 shifts according to the dynamic overlap parameter On to apply the final orthogonal strip W. Vertical line W2 is aligned with the endpoint EP of surface 52. Thus, the final orthogonal strip W of the wall routine is set at the endpoint EP of surface 52.

[0078] AMS 12 offers significant advantages. AMS 12 provides automated fluid application. AMS 12 increases productivity by allowing human operators to focus on other aspects of the project while AMS 12 is spraying surface 68. AMS 12 is capable of navigating within a room and applying fluid to surface 68. As AMS 12 approaches a feature of surface 52, control module 24 executes an overlap adjustment routine. The dynamic overlap routine minimizes the difference between the overlap and the initial overlap parameters when positioning AMS 12, ensuring that the final orthogonal strip applied to surface 52 is at the endpoint EP of surface 52. Applying the complete final orthogonal strip prevents gaps from being created at the endpoint EP of surface 52, gaps that would otherwise need to be covered by AMS 12 or the user. In this way, the overlap adjustment routine improves efficiency and reduces material costs. Applying the complete final orthogonal strip provides a smooth transition from the along-wall routine to the additional routine.

[0079] Figure 2A This is a top-view diagram of AMS 12. Figure 2B This is a schematic diagram of the spray environment, showing the non-spray area 56 and the indicator 54. Figure 2A and Figure 2B We will discuss this together.

[0080] Control module 24 is configured to control the injection and movement of AMS 12 based on signals received from indicator sensor 40. Indicator sensor 40 can be any desired configuration suitable for sensing the presence of indicator 54. In some examples, AMS 12 may include multiple indicator sensors 40 in various configurations, thereby facilitating the use of various types of indicators 54 by AMS 12.

[0081] Indicator 54 is placed near non-spraying area 56. Indicator 54 may be placed on the ground near non-spraying area 56. In some examples, indicator 54 may be adhered to or placed on vertical surface 54. Multiple indicators 54 may enclose non-spraying area 56 to indicate the lateral boundary of non-spraying area 56. For example, first indicator 54 may be placed at the entrance of the gap, and second indicator 54 may be placed at the exit of the gap. Control module 24 may control the movement and spraying of AMS 12 according to a spray adjustment routine based on the entrance indicator in AMS 12 encountering indicator 54. Control module 24 may control the movement and spraying of AMS 12 according to a wall-following routine based on the exit indicator in AMS 12 encountering indicator 54.

[0082] Control module 24 can cause AMS 12 to operate according to a spray adjustment routine based on indicator 54 sensed by indicator sensor 40. During the spray adjustment routine, control module 24 controls the spraying and movement of AMS 12 to prevent AMS 12 from applying spray fluid in non-spraying areas 56. Control module 24 can execute specific instructions regarding the spray adjustment routine based at least in part on indicator 54 sensed by indicator sensor 40. For example, control module 24 can cause AMS 12 to move laterally across non-spraying areas 56 until it encounters another indicator 54, at which point control module 24 restarts the wall-traveling routine after having passed non-spraying areas 56. In some examples, control module 24 can cause AMS 12 to spray portions of the target surface 52 surrounding non-spraying areas 56 (such as above and below the window forming non-spraying areas 56) and then resume the wall-traveling routine after having passed non-spraying areas 56. In some examples, control module 24 can cause AMS 12 to stop at indicator 54 until further instructions are received from the user. Instructions for various injection adjustment routines can be stored in memory 42 and invoked based on the encountered indicator 54.

[0083] In some examples, indicator 54 is programmable to provide AMS 12 with relevant information about the non-spraying area 56. For example... Figure 2BAs shown, the target surface 52 may include various non-jetting areas 56 with various configurations, such as windows and doorways. In some examples, a first subset of indicators 54 may be programmed to be associated with a first type of non-jetting area 56 (e.g., a window), and a second subset of indicators 54 may be programmed to be associated with a second type of non-jetting area 56 (e.g., a door). When indicator sensor 40 detects an indicator 54 in the first subset, information from that indicator 54 can provide details about the first type of non-jetting area 56 associated with that indicator 54. For example, the first subset of indicators 54 may be associated with a window that is above ground level and has a certain width. Control module 24 may control the spraying of AMS 12 relative to the first type of non-jetting area 56 based on information from the indicators 54, such that AMS 12 applies fluid around but not within the non-jetting area 56. When AMS 12 encounters an indicator 54 in the second subset, information from that indicator 54 can inform control module 24 about the second type of non-jetting area 56.

[0084] It should be understood that the injection commands associated with each subset of the indicator 54 and the type of the non-injection area 56 can be stored in the memory 42 of the control module 24 and are invoked based on the type of the non-injection area 56 indicated by the indicator 54. For example, injection commands for type A and type B window openings can be stored in the memory 42. A first subset of the indicator 54 can indicate that the non-injection area 56 is window type A, and a second subset of the indicator 54 can indicate that the non-injection area 56 is window type B. The control module 24 can invoke the injection commands from the memory 42 based on a specific indicator 54 sensed by the indicator sensor 40.

[0085] In some examples, control module 24 can control the spraying relative to gap 56 based on data from indicator sensor 40 and distance sensor 38. For example, control module 24 can enter spray adjustment mode based on AMS 12 encountering indicator 54 and determine a specific spraying routine to be executed based on data from distance sensor 38. In such an example, when encountering the inlet indicator in indicator 54, control module 24 drives AMS 12 forward relative to target surface 52. As AMS 12 moves forward relative to the inlet indicator in indicator 54, control module 24 receives distance data from distance sensor 38 (such as a forward-facing wall sensor 38a). Control module 24 can determine the type of non-spraying area 56 based on the distance data. For example, if the distance data indicates a sudden increase in distance, control module 24 can classify non-spraying area 56 as a doorway, recall the spray adjustment routine associated with the doorway from memory 42, and cause AMS 12 to apply fluid to target surface 52 according to the doorway spray adjustment routine. If the distance data indicates a stable distance, the control module 24 can classify the non-jetting area 56 as a window, recall the jet adjustment routine associated with the window from the memory 42, and instruct the AMS 12 to apply fluid to the target surface 52 according to the window jet adjustment routine. The type of jet adjustment routine can be stored in the memory 42 prior to operation. In some examples, the AMS 12 can be configured to operate according to two types of jet adjustment routines, one based on an increased distance detected by the wall sensor 38a and the other based on a stable distance detected by the wall sensor 38a. While a jet adjustment routine based on a stable distance detected by the wall sensor 38a has been discussed with regard to window openings, it should be understood that a jet adjustment routine can be associated with any desired type of non-jetting area 56 that does not have an increased distance at the location of the wall sensor 38a, such as an arch, a common box, etc.

[0086] Control module 24 causes AMS 12 to apply fluid strips according to the wall-following routine until indicator sensor 40 detects indicator 54. When indicator sensor 40 detects indicator 54, control module 24 executes the injection adjustment routine and causes AMS 12 to operate according to the injection adjustment routine. As described above, in some examples, control module 24 can execute various injection adjustment routines based on the information provided by indicator 54. Control module 24 can cause AMS 12 to stop injection and move laterally a set distance relative to target surface 52, or until another indicator 54 is encountered; can cause AMS 12 to apply fluid relative to non-injection area 56; and / or can cause AMS 12 to stop operation and wait for further user instructions, etc.

[0087] The injection system 10 and AMS 12 offer significant advantages. An indicator 54 is positioned near the non-injection area 56 and indicates its presence to the AMS 12 during operation. An indicator sensor 40 senses the indicator 54 and can provide information to the control module 24, allowing the control module 24 to execute different injection routines based on the presence of the indicator 54, and in some examples, based on data from the distance sensor 38. The indicator 54 and indicator sensor 40 prevent the AMS 12 from applying injection fluid to the non-injection area 56, reducing material costs and providing a more efficient injection process. Therefore, the AMS 12 can autonomously navigate and inject relative to the non-injection area 56, increasing productivity by allowing users to focus on other aspects of the project while the AMS 12 is running. Furthermore, the indicator 54 can be placed at any desired location during injection, allowing users to define the non-injection area 56 according to their expectations and the requirements of the specific job.

[0088] Figure 3 This is an isometric view of an Automated Mobile Sprayer (AMS) 12ʹ. In the example shown, AMS 12ʹ is an unmanned aerial vehicle (UAV) configured to apply fluids, such as paint, varnish, water, oil, colorant, topcoat, coating, and solvent, to a surface. The example surface can be an internal surface, such as a wall, or an external surface, such as a building, bridge, utility tower, and vehicle. AMS 12ʹ includes a spray module 16ʹ, a base 18ʹ, a sensor 22, and a lift rotor 62. Spray module 16 includes a nozzle 36 and a spray pipe 64. AMS 12ʹ may include a reference AMS 12 ( Figures 1A to 1C The additional components described include a control module, user interface, control valves, etc. Sensor 22 may include a distance sensor, similar to wall sensor 38a. Figure 1C and Figure 2A ) and path sensor 38b ( Figure 1C and Figure 2A ), and in some examples, may include an indicator sensor 40. Similar to fluid supply source 14 ( Figure 1A The fluid supply source can be located on or outside the AMS 12ʹ, and the fluid is connected to the AMS 12ʹ.

[0089] The base 18ʹ supports various components of the AMS 12ʹ. A lift rotor 62 extends from the base 18ʹ and provides lift to the AMS 12ʹ during flight. An injection pipe 64 extends from the base 18ʹ and is configured to supply fluid from the AMS 12ʹ to a nozzle 36. The nozzle 36 is attached to the injection pipe 64 and configured to atomize the fluid and generate a fluid jet fan SF. In the example shown, the nozzle 36 is oriented to generate a vertical jet fan for applying horizontal stripes; however, it should be understood that the nozzle 36 can be adjusted to different orientations to generate a horizontal jet fan, or alternatively, to be oriented to generate a horizontal jet fan for applying vertical stripes or to generate any other desired jet configuration.

[0090] Sensor 22 is mounted on 18ʹ and is essentially similar to the one about Figures 1A to 2B The sensor 22 is discussed. A distance sensor 38 is shown. It should be understood that the AMS 12ʹ can include any number of distance sensors 38 as needed. The distance sensors 38 can generate distance data about the distance to features on surface 52. The distance sensors 38 can be oriented for viewing in any direction relative to the AMS 12ʹ to generate distance data about features in the travel path of the AMS 12ʹ, including above and below the AMS 12ʹ. The distance sensors 38 generate distance data, and the control modules of the AMS 12ʹ, such as control module 24 (… Figures 1B to 1C The overlap of each applied strip can be redrawn as the AMS 12ʹ approaches the feature to compensate for the feature's position. Similar to control module 24, the control module of the AMS 12ʹ can determine dynamic overlap parameters during operation and control the movement and spraying of the AMS 12ʹ based on the determined overlap parameters.

[0091] Similar to AMS 12, AMS 12ʹ can apply fluid to surface 52 according to a wall-following routine and can adjust the routine operation according to overlap. Unlike AMS 12, AMS 12ʹ is a vehicle that can travel in any direction within the ZY plane to apply fluid, including vertically up and down, horizontally left and right, and / or combinations thereof. AMS 12ʹ travels horizontally relative to surface 52 to apply horizontal strips and vertically relative to surface 52 to apply vertical strips. The control module can adjust the initial overlap parameters during operation to adjust the overlap between adjacent strips. The control module can adjust the overlap parameters based on the interval between the current fluid strip and a feature of surface 52. Control module 24 adjusts the overlap parameters based on the remaining travel distance to the endpoint of surface 52. The control module can determine the travel distance based on distance data provided by distance sensor 38.

[0092] The control module adjusts the initial overlap parameters so that the final vertical or horizontal positive flow strip is applied as a full-width strip onto surface 52 via AMS 12ʹ. Dynamic overlap adjustment ensures that the final strip does not leave unsprayed gaps between the final strip and the features of surface 52, while maintaining sufficient overlap between adjacent strips to provide the desired coverage. During overlap adjustment mode, AMS 12ʹ continues to travel along surface 52 while fluid is applied.

[0093] During the overlap adjustment routine, the control module determines the dynamic overlap parameters before shifting AMS 12ʹ to apply the next strip. The control module receives look-ahead data from distance sensor 38 and determines the distance to the feature of surface 52 based on the look-ahead data. The control module determines the number of strips to be applied to the feature of surface 52. During the overlap adjustment routine, the overlap parameters are adjusted such that the final orthogonal spray relative to surface 52 is applied at the desired position relative to the feature of surface 52 to prevent any gaps or uneven spraying.

[0094] During the overlap adjustment routine, the control module determines the remaining distance to the endpoint EP associated with the feature and, based on the remaining distance and other operating parameters, such as the width of the spray fan, the type of spray head, and the desired coverage area, determines new overlap parameters. The initial overlap parameters are adjusted based on these variables, and the control module controls the movement and spraying of the AMS 12ʹ based on the dynamic overlap parameters determined by the control module.

[0095] The control module determines the dynamic overlap parameters based on a comparison between injection parameters and threshold parameters (such as distance or traversal count), as referenced above. Figures 1A to 1D For a more detailed discussion. If the injection parameters are greater than the threshold parameters, the control module can cause AMS 12ʹ to continue operating according to the along-wall routine. The control module can initiate the overlap adjustment routine based on injection parameters that are equal to or less than the threshold parameters.

[0096] For example, the control module receives look-ahead data from at least one distance sensor 38. Based on the look-ahead data, the control module determines injection parameters, such as the distance to the feature. The control module compares the injection parameters with a threshold parameter. If the injection parameter is less than the threshold distance, the control module initiates an overlap adjustment routine.

[0097] During the overlap adjustment routine, the control module determines one or more dynamic overlap parameters and controls the movement and spraying of AMS 12ʹ based on these parameters. The control module determines an initial remaining traversal count of the number of strips required to completely cover surface 52 to reach the endpoint EP of surface 52. This initial remaining traversal count can be calculated by dividing the distance to the endpoint EP by the overlap parameter applied to each strip width.

[0098] The control module determines the state of the remaining traversal count, such as whether the remaining traversal count is an integer or a fraction. If the remaining traversal count is a fraction, the control module adjusts the remaining traversal count to an adjusted integer. A remaining traversal count that is an integer rather than a fraction provides the full-width final orthogonal stripe W at the feature of surface 52. Figure 1D The fractional traversal count can be adjusted up or down to the nearest integer. Adjusting to the next larger integer ensures that each section of surface 52 receives at least two fluid applications. Adjusting to the nearest adjacent integer minimizes any difference between the dynamic overlap parameter and the initial overlap parameter. If the remaining traversal count is an integer, the control module can use the initial overlap parameter to shift AMS 12ʹ to apply the next fluid strip.

[0099] The control module determines dynamic overlap parameters based on an adjusted traversal count and the remaining distance to the feature. The remaining distance to the feature on surface 52 can be divided by the adjusted traversal count to determine the first dynamic overlap parameter. The control module can then orthogonalize AMS 12ʹ to the strip axis and shift it relative to surface 52 according to the dynamic overlap parameter. AMS 12ʹ is considered to apply a fluid strip along the first axis, and AMS 12ʹ is shifted along a second axis to apply an adjacent fluid strip, which is transverse to the first axis and, in some examples, orthogonal to the first axis.

[0100] After shifting and applying adjacent strips, the control module can repeat the overlap adjustment routine to determine second and subsequent dynamic overlap parameters. The control module determines the distance to the feature based on look-ahead data, determines the second dynamic overlap parameter, and controls the movement of AMS 12ʹ based on the second dynamic overlap parameter. The control module can continue to determine additional overlap parameters throughout the operation and control the operation of AMS 12ʹ based on these overlap parameters. The control module can continue to run AMS 12ʹ in overlap adjustment mode until the endpoint is reached.

[0101] Figure 4 This is a flowchart illustrating method 100. Method 100 uses an automated moving injector, such as AMS 12 (…). Figures 1A to 1C as well as Figure 2A ) or AMS 12ʹ ( Figure 3 The method of ejecting fluid. In step 102, the AMS control module, such as control module 24 ( Figure 1B , Figure 1C and Figure 2A The AMS executes a wall-following routine to apply fluid to a target surface, such as surface 52, according to the wall-following routine. In the wall-following routine, the AMS is spaced a first distance from the target surface. This distance is from a distance sensor oriented towards the surface, such as from wall sensor 38a. Figure 1C and Figure 2A Sensor data is provided to the control module, which controls the movement of the AMS, ensuring that the AMS maintains a desired orientation relative to the surface and is spaced apart from it. For example, the AMS can remain parallel to the target wall and spaced a first distance from it. The AMS applies a first fluid strip to the target wall. The control module shifts the AMS relative to the wall based on initial overlap parameters. For example, the control module can activate wheel 26 ( Figures 1A to 1C as well as Figure 2A ) wheel motor 32 ( Figure 1C and Figure 2A This allows the AMS to be laterally displaced relative to the surface. The control module can be based on feedback from the wheel motor, data from sensors configured to sense wheel rotation, and data from path sensors such as path sensor 38b. Figure 1C The distance traveled is determined by forward-looking data or in any other desired manner. AMS continues to apply fluid according to the along-wall routine until the operating parameters reach the threshold.

[0102] In step 104, the control module compares the operating parameters with thresholds. The thresholds are based on the distance between the AMS and the target wall endpoint. The endpoint is the location where the AMS ends its along-wall routine relative to a wall feature. For example, the endpoint can be located at or separated from the feature. The operating parameters can be determined based on look-ahead data provided by the AMS's path sensors. For example, the operating parameters could be the remaining distance to the endpoint and / or the number of remaining spray passes to the endpoint, etc. The thresholds could be a threshold distance and / or a threshold pass count, etc.

[0103] In step 106, the control module compares the operating parameters with a threshold to determine whether the operating parameters are equal to or less than the threshold. If the answer to step 106 is no, the method returns to step 102, and AMS continues to run according to the wall-following routine and in wall-following mode. If the answer to step 106 is yes, the method proceeds to step 108, the control module initiates the overlap adjustment routine, and AMS runs in overlap adjustment mode.

[0104] Figure 5 This is a flowchart illustrating method 200. Method 200 is a process for automatically moving injectors based on an overlap adjustment routine, such as AMS 12 (…). Figures 1A to 1C , Figure 2A ) and AMS 12ʹ ( Figure 3 The method of applying fluid. A dynamic overlap routine positions the AMS (Advanced Motion Stream) so that the final spray relative to the target wall is applied at the endpoint of the target wall, preventing gaps and uneven spraying. As the AMS approaches the end of the wall-following routine, an overlap adjustment routine further provides uniform fluid application.

[0105] In step 202, the control module of AMS, such as control module 24 ( Figure 1B , Figure 1C and Figure 2A ), to determine the features on the target wall and / or the endpoints associated with those features (e.g., surface 52 ( Figures 1A to 2B The endpoint EP () Figure 1C , Figure 1D and Figure 2A The endpoint is the location where the AMS stops the wall-following routine and ends the spraying or transitions to another routine. For example, the endpoint can be located at a feature or spaced apart from a feature. This is based on distance data from a distance sensor, such as the path sensor of the AMS (e.g., path sensor 38b). Figure 1C and Figure 2A The forward-looking data provided determines the distance to the destination.

[0106] In step 204, the control module determines the remaining traversal count of the number of strips that need to be applied to the target surface to reach the endpoint of the target surface. The control module determines the remaining traversal count before shifting the AMS to apply the next fluid strip. The remaining traversal count is determined based on the distance to the endpoint and the width of the additional coverage provided by each application traversal of the AMS. For example, the remaining traversal count can be determined by dividing the distance to the endpoint by the width of the additional fluid applied in each jet traversal.

[0107] In step 206, the control module determines the state of the remaining traversal count, such as whether the remaining traversal count is a fraction or an integer. If the remaining traversal count is an integer, the answer is yes, and method 200 proceeds to step 210, where the remaining traversal count is used as the adjusted remaining traversal count. If the remaining traversal count is a fraction, the answer is no, and method 200 proceeds to step 208.

[0108] In step 208, the fractional residual traversal count is adjusted to an adjusted residual traversal count that is an integer. The traversal count value of the fractional residual traversal count can be adjusted up or down to the nearest neighboring integer. In some examples, the fractional residual traversal count is adjusted to the nearest integer greater than the fractional residual traversal count. Adjusting to the next larger integer ensures that each portion of the target surface receives at least two fluid applications. In some examples, the fractional residual traversal count is adjusted to the nearest neighboring integer. Adjusting to the nearest neighboring integer minimizes any difference between the dynamic overlap parameters and the initial overlap parameters.

[0109] In step 210, dynamic overlap parameters are determined based on the adjusted remaining traversal count and the coverage width of each strip. The distance to the endpoint is divided by the adjusted remaining traversal count to provide the dynamic overlap parameters. The resulting distance is the dynamic overlap distance. The dynamic overlap percentage can be calculated based on the dynamic overlap distance and the width of the jet fan at the target surface. In some cases, the control module can compare the dynamic overlap percentage with a percentage threshold to determine whether the dynamic overlap percentage falls within a desired range defined by the percentage threshold. The dynamic overlap percentage can be adjusted to fall within the threshold range.

[0110] In step 212, the control module shifts the AMS relative to the target surface according to the dynamic overlap parameters. The control module shifts the AMS by a dynamic overlap distance relative to the target surface and applies a fluid strip at the new location.

[0111] In step 214, the control module determines whether additional fluid strips need to be applied to the target surface to reach the endpoint of the target surface. For example, the control module may determine whether additional strips are needed based on look-ahead data from the path sensor. If additional traversal is required, method 200 returns to step 202 and continues applying fluid strips according to the overlap adjustment routine. If the AMS has already reached the endpoint of the wall, no additional traversal is needed, and method 200 proceeds to step 216. In step 216, the control module terminates the wall-following routine and may stop spraying or start another spraying routine.

[0112] Figure 6 This is a flowchart illustrating method 300. Method 300 involves operating an automated moving injector (AMS), such as AMS12 ( Figures 1A to 1C , Figure 2A The method is based on an indicator, such as indicator 54 ( Figure 1A , Figure 2A and Figure 2B The data from the AMS applies fluid to the target surface. In step 302, the AMS is laterally displaced relative to the target surface and the jet fluid is applied to the target surface. For example, the control module of the AMS, such as control module 24 ( Figure 1C and Figure 2A This allows the AMS to be moved laterally and its spraying to be controlled. In some examples, in step 302, the control module causes the AMS to run according to the wall-following routine.

[0113] In step 304, the indicator sensor, such as indicator sensor 40 ( Figure 1B , Figure 1C and Figure 2A ), sense indicators encountered by AMS12, such as indicator 54 ( Figure 1A , Figure 2A and Figure 2B The indicator sensor generates indicator data, which can be a signal indicating that the indicator has encountered the indicator, and provides this indicator data to the control module. The indicator sensor of the sensing indicator indicates the presence of a non-jet area, which is the area of ​​the target surface where it is not intended to apply jet fluid.

[0114] In step 306, the control module controls the movement and spraying of the AMS relative to the target surface based on indicator data. For example, the control module can exit the along-wall routine and control the movement and spraying of the AMS according to the spraying adjustment routine. One or more spraying adjustment routines can be stored in the control module's memory, such as memory 42. Figure 1C and Figure 2A In some examples, the control module can drive the AMS forward relative to the target surface, based on distance sensors (such as wall sensors 38a). Figure 1C and Figure 2A The distance data generated determines the injection adjustment routine. The injection adjustment routine provides instructions to control module 24 for controlling the movement of the AMS and the injection of the AMS relative to the non-injection area. In some examples, the control module may exit the injection adjustment routine based on the indicator sensor sensing a second indicator indicating the end of the non-injection area. In some examples, after exiting the injection adjustment routine, the control module may resume injection according to step 302, for example, via a wall-following routine.

[0115] While the invention has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made without departing from the scope of the invention, and equivalents can be substituted for its elements. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from the basic scope of the invention. Therefore, it is intended that the invention be limited to the specific embodiments disclosed, but rather that the invention encompass all embodiments falling within the scope of the appended claims.

Claims

1. An automated mobile ejector (AMS) configured to spray fluid onto a target surface, the AMS comprising: A movable base is configured to move along a first axis of the target surface; The jetting module, supported by the movable base, is movable along a second axis of the target surface and configured to jet a fluid jet strip onto the target surface oriented parallel to the second axis, which is orthogonal to the first axis. At least one path sensor is oriented to look ahead along the travel path of the AMS and generates look-ahead data about the distance to features in the travel path; and The control module is configured as follows: Receive the look-ahead data from the at least one path sensor; Determine the first distance to the feature; A first overlap parameter of the vertical strips is determined based on the first distance, the first overlap parameter indicating the first degree of overlap between consecutive vertical strips sprayed by the spraying module; Based on the first overlap parameter for a first portion of the target surface, the moving base and the spraying module are controlled to spray at least one vertical strip; Determine a second distance to the feature, the second distance being shorter than the first distance; A second overlap parameter is determined based on the second distance, the second overlap parameter indicating the second degree of overlap between consecutive vertical strips sprayed by the spraying module; as well as Based on the second overlap parameter for another portion of the target surface that is different from the first portion of the target surface, the moving base and the spraying module are controlled to spray at least one vertical strip.

2. The AMS according to claim 1, wherein the first overlap parameter is different from the second overlap parameter.

3. The AMS of claim 1, wherein the difference between the first overlap parameter and the second overlap parameter is based on a repositioning movement error caused by repositioning the AMS between vertical strips, the repositioning movement error occurring between the first distance measurement and the second distance measurement.

4. The AMS of claim 3, wherein the control module is configured to control the movement of the mobile base based on the first overlap parameter if the magnitude of the repositioning movement error is less than a threshold.

5. The AMS according to any of the preceding claims, wherein the control module is configured to dynamically adjust the overlap distance by which the AMS is displaced relative to the target surface, the overlap distance being provided by an overlap parameter determined by the control module.

6. The AMS according to any one of claims 1 to 4, wherein the control module is configured to determine a final overlap parameter and control the movable base and the spraying module based on the final overlap parameter to spray a final vertical strip such that the final vertical strip is applied to the target surface at its endpoint.

7. The AMS according to any one of claims 1 to 4, wherein the at least one path sensor is a distance sensor.

8. The AMS of claim 1, wherein during the wall-mounted routine, the overlap distance between adjacent fluid jet strips has a set value.

9. The AMS according to any one of claims 1 to 4, wherein the mobile base is supported on the ground.

10. The AMS of claim 6, wherein wheels support the mobile base on the ground.

11. The AMS according to any one of claims 1 to 4, wherein the AMS is an unmanned aerial vehicle (UAV).

12. The AMS of claim 8, wherein the injection module is fixed to the movable base such that the injection module does not move relative to the movable base.

13. The AMS of claim 8, wherein the first axis is a vertical axis and the second axis is a horizontal axis.

14. The AMS of claim 8, wherein the first axis is a horizontal axis and the second axis is a vertical axis.

15. The AMS according to claim 1, wherein the control module is configured to: The first overlap parameter is determined based on the count of vertical stripes with full width required to uniformly apply the fluid jet to the target surface; Based on the repositioning movement error, it is determined that a vertical strip with a certain width is needed to uniformly apply the fluid jet to the target surface; as well as The second overlap parameter is calculated based on the vertical stripe that requires the required width of the portion.

16. An automated mobile ejector (AMS) configured to spray fluid onto a target surface, the AMS comprising: A movable base is configured to move horizontally along the target surface; A jetting module supported by the movable base, the jetting module being movable relative to the movable base and the target surface along a vertical axis, and configured to jet a fluid jet strip onto the target surface; At least one path sensor is oriented to look ahead along the travel path of the AMS and generates look-ahead data about the distance to features in the travel path; and The control module is configured as follows: Receive the look-ahead data from the at least one path sensor; Determine the first distance to the feature; Compare the first distance with the threshold; Based on the fact that the distance to the feature exceeds a threshold, the AMS is displaced relative to the target surface according to the wall-following routine; as well as Based on the distance to the feature being equal to or less than the threshold, the AMS is shifted relative to the target surface according to the overlap adjustment routine.

17. The AMS of claim 16, wherein the control module is configured to: Determine the remaining traversal count, which is a count of the number of fluid jet strips that need to be applied to the target surface to reach the feature; The remaining traversal count is adjusted to an adjusted remaining traversal count, wherein the adjusted remaining traversal count is an integer; The dynamic overlap distance is determined based on the distance to the endpoint and the adjusted remaining traversal count. as well as The AMS is shifted by the dynamic overlap distance relative to the target surface to a first application point, and the AMS applies the fluid jet strip at the first application point.

18. A method for injecting fluid onto a target surface using an automated mobile injector (AMS), the method comprising: According to the wall-following routine, the AMS applies jet fluid to the target surface, wherein the control module of the AMS causes the AMS to shift relative to the target surface by an initial overlap distance between each strip applied to the target surface; The control module determines the operating distance to the features of the target surface based on look-ahead data generated by the path sensor of the AMS; The control module compares the operating distance with a threshold. as well as The control module initiates the overlap adjustment routine based on a comparison indicating that the operating distance is equal to or less than the threshold. The control module adjusts the initial overlap distance to a dynamic overlap distance and shifts the AMS relative to the target surface by the dynamic overlap distance during the overlap adjustment routine.

19. The method of claim 18, wherein the overlap adjustment routine comprises: The remaining traversal count is determined by the control module based on the operating distance. The remaining traversal count is the count of strips to be applied to the target surface to reach the feature.

20. The method of claim 19, further comprising: The control module determines the state of the remaining traversal count; as well as Based on the state being a fraction, the control module adjusts the remaining traversal count to an adjusted traversal count, wherein the adjusted traversal count is an integer.

21. The method of claim 20, wherein based on the state being a fraction, the control module adjusts the remaining traversal count to the adjusted traversal count, wherein the adjusted traversal count being an integer includes: Increase the traversal count value of the remaining traversal count so that the adjusted traversal count is greater than the remaining traversal count.

22. The method of claim 21, wherein increasing the traversal count value comprises increasing the traversal count value to a larger neighboring integer.

23. The method of claim 20, wherein based on the state being a fraction, the control module adjusts the remaining traversal count to the adjusted traversal count, wherein the adjusted traversal count being an integer includes: Reduce the traversal count value of the remaining traversal count so that the adjusted traversal count is less than the remaining traversal count.

24. The method of claim 23, wherein reducing the traversal count value comprises reducing the traversal count value to a smaller adjacent integer.

25. The method of claim 20, wherein, based on the state being a fraction, the control module adjusts the remaining traversal count to the adjusted traversal count, wherein the adjusted traversal count being an integer includes: The traversal count value of the remaining traversal count is adjusted to a neighboring integer with the value closest to the traversal count value, such that the adjusted traversal count is greater than or less than the remaining traversal count.

26. The method of claim 20, further comprising: The first dynamic overlap distance is determined by dividing the operating distance by the adjusted traversal count.

27. The method of claim 26, further comprising: The control module drives the AMS relative to the target surface to the first dynamic overlap distance.

28. The method of claim 27, further comprising: After driving the first dynamic overlap distance with the AMS, the remaining distance to the endpoint of the target surface is determined.

29. The method of claim 28, further comprising: Based on the fact that the AMS is at the endpoint, exit the overlap adjustment routine.

30. The method of claim 28, further comprising: Based on the additional application required to reach the endpoint by AMS, a second dynamic overlap distance is determined based on the look-ahead data from the path sensor and a second adjusted traversal count, wherein the second adjusted traversal count is the adjusted traversal count minus one traversal. as well as The control module drives the AMS relative to the target surface to the second dynamic overlap distance.

31. The method of claim 18, wherein determining the operating distance to a feature of the target surface by the control module comprises: Features in the travel path of the AMS are sensed by the path sensor of the AMS; Based on sensor data from the path sensor, the distance to the feature is determined; as well as The distance to the feature is modified by an interval factor to provide the operational distance.

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