Wiping process in robotic paint repair

Abstract

A wiping system for a robotic repair unit is presented that includes a driven robot arm having a motor, a connection mechanism coupled to the driven robot arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The driven robot arm is driven by the motor to move the wiping medium. The driven robot arm is configured to move the wiping medium toward or away from a work surface. The drive arm is configured to urge the wiping medium toward the work surface during a wiping operation. During the wiping operation, the wiping medium is driven against the surface by the wiping motor.

Description

[Background technology]

[0001] In the automotive industry, it is often necessary to prepare the surfaces of vehicle parts or replacement parts (e.g., bumpers) for various purposes (e.g., painting) or to repair the surfaces of automotive parts or replacement parts due to defects created during painting or coating. A typical surface preparation process includes, for example, physically abrading the automotive surface, i.e., "scuffing." Typical repair operations often include, for example, sanding and polishing. Different tools, materials, and fluids may be utilized for surface preparation and repair of surface defects. Summary of the Invention

[0002] A wiping system for a robotic repair unit is presented that includes a driven robot arm having a motor, a connection mechanism coupled to the driven robot arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The driven robot arm is driven by the motor to move the wiping medium. The driven robot arm is configured to move the wiping medium toward or away from a work surface. The drive arm is configured to urge the wiping medium toward the work surface during a wiping operation. During the wiping operation, the wiping medium is driven against the surface by the wiping motor.

[0003] Removal of process fluids or slurry during the defect repair process has been shown to be beneficial to the final workpiece product and can be accomplished by adding a fluid removal step following any polishing treatment. It has been shown that the limiting factor in wiping efficiency is water removal. Wiping parameters should be selected to drive water off the pad so that the pad operates as close to steady state as possible with respect to water retention while still removing a high percentage of the slurry from the repair. This removal step previously required a human operator to manually wipe the workpiece surface to remove the process fluid. Including the first tool, second tool, and fluid removal tool all on a single driven robotic arm, and potentially having a single force control unit, streamlines the process of effectively repairing automotive surfaces. [Brief description of the drawings]

[0004] The present disclosure may be more fully understood from the following detailed description of various embodiments of the disclosure when considered in conjunction with the accompanying drawings, in which: [Figure 1] 1 is a schematic diagram of a robotic paint repair system in which embodiments of the present invention are useful; [Diagram 2] 1 is a schematic diagram of a paint repair robot in which embodiments of the present invention are useful; [Diagram 3] FIG. 1 is a schematic diagram of a dual mount end effector system of a paint repair robot, according to embodiments herein. [Figure 4A] 1 is an image result of a haze quality experiment. [Figure 4B] 1 is an image result of a haze quality experiment. [Figure 5A] 1 illustrates a dual mount end effector system having a fluid removal tool, according to embodiments herein. [Figure 5B] 1 illustrates a dual mount end effector system having a fluid removal tool, according to embodiments herein. [Figure 6] 1 illustrates a possible placement of a fluid removal tool on a dual mount end effector system. [Figure 7] 1 illustrates an embodiment of a fluid removal tool. [Figure 8] FIG. 1 illustrates a schematic diagram of a robotic repair system, according to embodiments herein. [Figure 9] 1 illustrates a method for performing defect repair operations according to an embodiment herein. [Figure 10A-1] 1 illustrates a wiping medium according to an embodiment herein. [Figure 10A-2] 1 illustrates a wiping medium according to an embodiment herein. [Figure 10A-3] 1 illustrates a wiping medium according to an embodiment herein. [Figure 10A-4] 1 illustrates a wiping medium according to an embodiment herein. [Figure 10B] 1 illustrates a wiping medium according to an embodiment herein. [Figure 10C-1] 1 illustrates a wiping medium according to an embodiment herein. [Figure 10C-2] 1 illustrates a wiping medium according to an embodiment herein. [Figure 11A] 1 illustrates a wiping system according to an embodiment of the present disclosure. [Figure 11B] 1 illustrates a wiping system according to an embodiment of the present disclosure. [Figure 12A] 1 illustrates a vacuum attachment for a fluid removal system, according to an embodiment herein. [Figure 12B] 1 illustrates a vacuum attachment for a fluid removal system, according to an embodiment herein. [Figure 12C] 1 illustrates a vacuum attachment for a fluid removal system, according to an embodiment herein. [Figure 12D] 1 illustrates a vacuum attachment for a fluid removal system, according to an embodiment herein.

[0005] In the drawings, like reference numbers refer to like elements. The above-identified drawings may not be drawn to scale and illustrate various embodiments of the present disclosure, however, other embodiments are also contemplated, as noted in the Detailed Description. In all cases, the disclosure describes the disclosure disclosed herein by way of representing exemplary embodiments, and not by way of express limitation. It should be understood that numerous other modifications and embodiments may be devised by those skilled in the art that are within the scope and spirit of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] The present disclosure provides an automated system and method using a robotic repair unit having an end-of-arm system mounted with tools for treating (e.g., scuffing, sanding, polishing, etc.) an object surface, and a fluid, slurry, or debris removal tool that may be utilized before, after, and / or during such process steps. The processing tool may be mounted on an end effector at the end of a driven robot arm along with a fluid removal tool so that it can move between various areas on a workpiece. The process tool may include a functional component configured to contact and prepare the object surface, one or more sensors configured to detect work status information of the end effector tool, a dispenser for fluid while the functional component contacts and prepares the object surface, and / or a control circuit that receives signals from the sensors and processes the signals to generate status information for the tool. The controller may also calculate the wiped area, for example, the total number of uses, duration of use, saturation of fluid removal, and rest periods for drying. The fluid removal tool may also include one or more sensors configured to detect work state information of the tool, a force control unit or end effector that enables movement or application of force by the fluid removal tool to a work surface.

[0007] FIG. 1 is a schematic diagram of a robotic paint repair system in which embodiments of the present invention are useful. The system 100 generally includes two units, a visual inspection system 110 and a defect repair system 120, each of which may include subunits. Both systems may be controlled by motion controllers 112, 122, respectively, which may receive instructions from one or more application controllers 150. The application controllers may receive input from or provide output to a user interface 160. The repair unit 120 includes a force control unit 124 that may be in communication with an end effector 126. As shown in FIG. 1, the force control unit 124 may be coupled to either end effector 126, each of which is coupled to a tool 128. The tool 128 may be configured as further described, such as those described in U.S. Provisional Patent Applications Nos. 62 / 940950 and 62 / 940960, both filed November 2, 2019, in one embodiment. However, other arrangements are expressly contemplated. The visual inspection unit 110 can detect defects on the vehicle surface 130, which can then be repaired by the repair unit 120.

[0008] FIG. 2 is a schematic diagram of a paint repair robot that may be useful in embodiments of the present invention. The robot repair unit 200 has a base 210 that may be stationary in some embodiments. In other embodiments, the base 210 may move in any of six dimensions: translation, or rotation about the x-axis, y-axis, and / or z-axis. For example, the robot 200 may have a base 210 fixed to a rail system configured to move with the vehicle being repaired, or may be mounted to a wall or ceiling transport device. Depending on the defect location, the robot 200 may need to move closer to or farther from the vehicle, or may need to move higher or lower relative to the vehicle. A mobile base 210 may make repairs to hard to reach defects easier.

[0009] The robotic repair unit 200 has one or more tools 256 capable of interacting with a work surface. The tools 256 may include a back-up pad in one embodiment, or may include another suitable abrasive tool. During the abrasive operation, the tools 256 may have an abrasive disk or other suitable abrasive article attached using adhesive, hook and loop, clip system, vacuum, or other suitable attachment system. Because the tools 256 are mounted to the robotic repair unit 200, they have the ability to be positioned within the degrees of freedom provided by the robotic repair unit 200 (in most cases, six degrees of freedom), as well as within any other degrees of freedom with their reference coordinate system (e.g., compliant force control 230 unit).

[0010] 3 shows one embodiment of a dual mounted end effector system 320 on a robot arm 300. The robot arm 300 can move the end effector system 320 rotationally using a mounted adapter plate 310 and vertically using a joint 315. In some embodiments, the robot arm 300 can move such that both a first tool 330 or a second tool 340 can be positioned to interact with a workpiece. The system 320 alternates between operating the first tool 330 and the second tool 340 using a single force control unit mounted to the plate 310 as shown. The first and second use positions have one of the tools 330, 340 aligned to the force control.

[0011] During the painting or clearcoat repair process, a fluid may be dispensed onto the workpiece before, during, or after the application of either tool 330 or 340. This process fluid may combine with particulate matter from the process to form a fluid slurry. The particulate matter that makes up this slurry generally comes from the sanding process that is typically performed before the polish buffing step. Processing with tool 330 or 340 without first removing this slurry fluid can have adverse effects on the final paint surface. Such adverse effects include a dull or unbuffed appearance in the final paint product, or undesirable scratches or other damage, which may be caused by micro-scratches. Since removing the slurry before surface buffing is not standard for robotic repair systems, the improvement seen when the slurry was removed was unexpected. The dull or imperfect appearance is not observable on all buffed surfaces, but is most noticeable after the sanding slurry or particulate matter accumulates on the buffing pad. The adverse effects of accumulation on the buffing pad were demonstrated by experiments performed on clearcoat workpieces.

[0012] 4A-4B are image results of a haze quality experiment. In this experiment, a fluid removal defect repair process method was compared against a no fluid removal defect repair process method on sanded and buffed surfaces. To complete this experiment, the surface from 4A was sprayed with water, sanded, and buffed with small polish beads for 12 consecutive cycles, with the slurry fluid removed after each sanding step. Fluid removal was done manually using a wiping technique. Images of the buffed surface were captured after the 4th, 8th, and 12th sanding / buffing cycles and are referenced by 402, 404, and 406, respectively. FIG. 4B shows the results of a similar 12 cycle sanding and buffing test without fluid removal after the sanding step. Results after the 4th, 8th, and 12th sanding / buffing cycles are referenced by 410, 412, and 114, respectively.

[0013] As shown in Figures 4A and 4B, the removal of fluid between the sanding and buffing steps results in a reduced hazy appearance of the painted surface at the end of the repair process. The current practice utilized by some manufacturers is for a human operator to manually remove the slurry after sanding and before the buffing step. This manual step is completed by wiping the workpiece with an absorbent material, such as a towel or sponge, to remove any slurry or particulate matter that may cause defects in the final paint or clear coat product. As used herein, the term absorbent refers to a material that absorbs fluid when contacted with a solution or suspension. Absorbent materials may include voids or channels that can capture fluid or may include fibers designed to soak up moisture. Since many of the solutions used with abrasive materials are water-based, in some embodiments, absorbent refers to a hydrophilic material. Absorbent materials can be non-woven or woven materials.

[0014] The current process of having a human manually wipe the workpiece surface after each sanding step is time consuming. The processing time of automated paint buffing can be improved by streamlining or automating the fluid removal process steps.

[0015] It was thought that the wiping step could be eliminated entirely since the robotic system took over the defect repair process. Because a human operator typically completes the wiping step so that they can see the repair area for the subsequent polishing step, it was thought that the wiping step could be eliminated since the robot does not need to "see" the defect area to continue the polishing step. However, as can be seen by comparing Figures 4A and 4B, once the wiping step is reintroduced, the robotic repair process shows a clear improvement in completion across multiple defect repairs.

[0016] FIG. 5A shows a sanding tool system 500 having dual mounted tools 502 and 504. In one embodiment, the system 500 can be mounted on the end of an arm of a robotic repair unit. The tools 502 and 504 are coupled to end effectors 512 and 514, respectively. Both end effectors 512 and 514 are coupled to a force control unit (not shown in FIG. 5) attached to a mounting plate. The system 500 can rotate at least 180 degrees to allow either the tool 502 or the tool 504 to contact the workpiece in a single operation. Each of the tools 502 and 504 can be used for polishing, sanding, or other surface preparation purposes. The tool configuration of FIG. 5 also shows a fluid removal tool 506. In one embodiment, the fluid removal tool 506 is coupled to the sanding tool system 500 using fasteners 508. In the embodiment shown in FIG. 5, the fluid removal tool 506 is a passive removal tool that contacts and drags the slurry fluid across the surface. The fluid removal tool 506 may be a cloth, sponge, or other wiping medium.

[0017] 5A illustrates a passive removal system, in other embodiments, the fluid removal tool 506 is an active fluid removal tool that includes a moving system such as a vacuum or air knife. Similarly, while the systems and methods are described herein with respect to a linear, unidirectional wiping process, more complex motions such as rotational, orbital, or random orbital device motions are explicitly excluded.

[0018] In other embodiments, the fluid removal tool 506 is a semi-passive removal system, for example having a passive element 506 but an active moving element, for example a fastener 508 that can extend through a mechanical element. For example, the fluid removal tool 506 may incorporate a spring or pneumatic compliance source to allow compliance when pressure or force is applied. Alternatively, the fluid removal tool may be mounted using the same compliance tool as a sanding or buffing tool is mounted.

[0019] In some embodiments, the fluid removal tool 506 is positioned to be part of the rotational path of the system 500, for example, such that the wiping media 506 intersects the arc 520. Such an arrangement can allow the fluid removal tool 506 to contact the workpiece as the system 500 rotates between a first position where the tool 502 interacts with the surface and a second position where the tool 504 interacts with the surface. The fastener 508 can be a fixed member or the fastener 508 can also be utilized to couple the fluid removal tool 506 to a force control device. In some embodiments, the fastener 508 is dimensioned to position the fluid removal tool 506 on the arc of rotation 520, allowing the removal tool 506 to passively contact the workpiece surface as the robot switches between the tools 502 and 504 into their operating positions.

[0020] 5A shows an embodiment in which the system 500 alone is sufficient to remove the slurry material. The limiting factor for efficient wiping is the removal of water entrapped in the wiping media. If the wiping media can reach a steady state or near steady state where an amount of water is expelled from the pad similar to the amount entrapped in the wiping slurry, the wiping media can engage in numerous wiping operations before needing to be replaced or disposed of.

[0021] The water can be driven off in a variety of ways: it may be sufficient to use friction generated by contact between the wiping medium and the surface, or by spinning the wiping element between wiping strokes.

[0022] By making the robot trajectory such that the outer portion of the wiping pad remains engaged with the sanding slurry, wiping efficiency can be increased. FIG. 5B shows a schematic diagram of a wiping operation 550 in which a wiping element 560 engages with a slurry 552 formed in the repair of a defect 554. Note that instead of centering the wiping element 560 in the slurry 552 or on the defect 564, the wiping element is positioned off-center. As shown in FIG. 5B, the rotational speed increases from the center 564 of the wiping element 560 toward the edge 562. Thus, the outer edge of the wiping element 560 generates higher friction, and therefore more heat, than the center 564, where the speed is essentially zero. The robot trajectory may be programmed to rotate the wiping element 560 inward toward the defect 564, so that the center 564 of the wiping element 560 does not engage the slurry or engages the slurry only after the outer edge of the wiping element 560 has passed this region. In some embodiments, it is not necessary to remove all of the slurry 552, but rather to wipe and clean the area of ​​the defect 554 enough so that the area of ​​the defect 554 can be imaged to evaluate the repair of the defect 554. In such embodiments, the wiping element 560 may move in a direction 566 such that an outer portion of the wiping element 560 engages the slurry before the center 564.

[0023] 5A-5B show an embodiment in which the wiping element reaches steady-state or substantially steady-state operation without an external moisture removal tool, however, it is expressly contemplated that the wiping element 560 may also be exposed to or include a vacuum or heat source that evaporates entrained water, as discussed herein.

[0024] It is desirable to minimize the wiping operation time. Thus, a combination of robot trajectories, heat sources, vacuum sources, applied force to create friction, rotational speed, and / or air sources can be used to reduce the time required to wipe a sufficient amount of slurry from the defect area. Heat sources may include heat lamps, such as infrared heat lamps, or another heat source. Air sources may include airflow, fans, and the like. Vacuum may be provided in conjunction with wiping element 560 or separately from wiping element 560.

[0025] 6 illustrates a robotic system with a fluid removal tool, according to embodiments herein. System 600 may include tools 630 and 640 attached to end effectors 620a and 620b, which are secured or fastened to a force controller 660. Controller 660 is additionally fastened to a mounting plate 650, which may rotate at least 180° to properly position tools 630 and 640 for processing a workpiece surface. Fluid removal tools described herein may be fastened or mounted to end effectors 620a or 620b at attachment points such as 602, 604, and 606.

[0026] The fluid removal tool may be mounted in either tool position 630 or 640 such that, for example, rotating mounting plate 650 180 degrees swaps the relative positions of tools 630, 640. In some embodiments, as part of its movement, the fluid removal tool may move through the defect repair area.

[0027] In one embodiment, the fluid removal tool may be mounted substantially perpendicular to both tools 630, 640. Such an arrangement may readily allow for passive wiping or surface cleaning as the mounting plate 650 rotates when switching from tool 630 to 640. It may also be beneficial to dimension the tool mount such that the fluid removal tool is located on a radial arc of rotation to facilitate passive or semi-passive wiping.

[0028] In one embodiment, passive wiping involves providing contact between the wiping media and the workpiece surface solely through the rotation of the mounting plate 650, without any additional robotic or force control movement.

[0029] In another embodiment, semi-passive wiping involves providing contact between the wiping media and the workpiece surface while the mounting plate 650 is rotating, but some additional amount of force or movement of the fluid removal tool is also required to promote effective contact with the workpiece surface.

[0030] Semi-passive wiping may also include feeding the wiping media along a trajectory such that the outer regions of the wiping media engage the defect area first and pick up more liquid than the inner portions of the wiping media. Semi-passive wiping may also include selecting the rotational speed, applied force, and lateral movement speed of the wiping media when in contact with the surface being wiped. Semi-passive wiping may also include a heat source, air source, or vacuum to aid in fluid removal.

[0031] In another embodiment, active wiping may include having an additional robotic system or arm to facilitate contact between the fluid removal tool and the wiping system. Active wiping may include contact between the fluid removal tool and the wiping system that does not occur during rotation of the mounting plate 650. Active wiping may include pneumatic or other moving tools to move the fluid removal tool.

[0032] In addition, active wiping may also include another fluid removal aid, such as a heat source, an air source, or a vacuum, that is applied while the wiping medium is in contact with the surface or that is applied to the wiping medium between wiping operations.

[0033] In determining the placement of the fluid removal tools, the sensor, wiring, and plumbing requirements of the system 600 must be considered. Passive removal tools, such as wiping media, may be easier to place than active fluid removal tools, which may have additional mechanical requirements. For example, an air knife fluid removal tool may require an abundant clean dry air or vacuum supply. Fluid removal tools that utilize force control unit 660, a separate force control unit, or have additional sensor capabilities may have different alignment requirements.

[0034] Automating the fluid removal process presents several challenges compared to the manual fluid removal process currently utilized in industry. Problems arise in ensuring sufficient slurry removal. A human operator can observe the work surface during the wiping process to ensure that the fluid or slurry has been effectively removed. Although a robotic fluid removal system can include optical sensors to provide similar feedback, the timing allocated to the wiping operation does not lend itself to an iterative feedback system because every additional second increases the required dwell time and reduces the number of repairs that can be performed in a work shift. Additionally, as shown in FIG. 6, the space available in the end-of-arm system 600 is limited and additional sensors reduce the space available for the tool. Due to the difficulties associated with incorporating additional sensors, in some embodiments, an efficient and predictable fluid removal system that does not require visual confirmation is incorporated into the end-of-arm system 600.

[0035] The human operator also has the ability to adjust the applied pressure, use random hand movements (e.g., circular and linear wiping patterns), and adjust or repeat the process as needed. These variations in pressure and wiping techniques allow the operator to effectively and reliably clean the workpiece surface. Such irregular movements are difficult to program into a robotic counterpart.

[0036] Another variable considered by the human operator is the saturation of the wiping media. Once the wiping media is saturated, the operator can make adjustments for retention to expose non-saturated surface areas and promote more effective fluid removal. Based on saturation, the human operator may also be able to detect when the wiping media needs to be replaced. The human operator may also use very large wipes (i.e., large towels) that are difficult for the robot to manipulate. Also, the human operator may be able to quickly discard and grab new wiping material, whereas the robot may take much longer to complete this change. Described herein are several systems and methods that address these challenges.

[0037] It may therefore be desirable to select operating parameters that allow the wiping medium to approach or achieve steady-state operation. This may include automating the slurry dispensing process so that a known amount of fluid is consistently dispensed. The operation of the wiping system may then be calibrated so that a known amount of fluid is removed from the surface and then evaporated or otherwise removed from the wiping medium during each wiping cycle. This may include adjusting the rotational speed, lateral speed, or applied force of the wiping medium. It may also include selecting the trajectory of the wiping medium so that the majority of the absorbed fluid is entrained in the outer portion of the wiping medium.

[0038] FIG. 7 shows a fluid removal system 700 for an end-of-arm robotic repair unit. The fluid removal system 700 also allows for the wiping media to be exposed for wiping a surface, if necessary. In some embodiments, the wiping media is a non-saturated wiping media, e.g., a clean, unused or new wiping media or portion of a wiping media. In some embodiments, the wiping media is a previously used wiping media, e.g., a media that has been cleaned, de-debrised or not yet saturated with slurry material. The wiping media can continue to be used as long as it sufficiently removes slurry and debris from the surface. In some embodiments, the wiping media is effective as long as at least 70% of the slurry material is removed during operation. In some embodiments, removal of at least 75%, or at least 80%, or at least 85%, or at least 90%, or at least 95%, or at least 98%, or at least 99% of the slurry material is required to be effective.

[0039] In some embodiments, the wiping action releases the wiping medium 720 from the first roll 710a, thereby exposing a new portion of the wiping medium 720 for the next wiping action.

[0040] In another embodiment, the wiping medium is unwound from roll 710a and wound onto roll 710b, for example, periodically or continuously.

[0041] In one embodiment, the system 700 is mounted on the end of an arm system for robotic repair, for example, extending perpendicular to the dual mounted processing tool 712, 714. The fluid removal system 700, in one embodiment, comprises a fluid wiping medium 720 that extends from a first roller 710a to a second roller 710b. In one embodiment, the wiping medium 720 is under tension maintained by support rods 706 and support nodes 702. The nodes 702 form vertices in the wiping medium that act as contact points with the workpiece surface. The shape of the nodes 702 may vary depending on factors such as the wiping medium in some embodiments.

[0042] In one embodiment, the support rod 706 is coupled to a motion controller (704) that moves the node 702 in directions 732 and 734. This directional control may allow the motion controller to be programmed to move the wiping medium 720 in complex motions to allow the fluid removal system 700 to remove fluid more efficiently. For example, it has been found that between sanding and polishing steps, fluid must be removed from the defect area. However, not all of the fluid needs to be captured on the wiping medium 720. For example, movement of the support rod 706 and node 702 in direction 736 may cause fluid to be shaken or driven away from the immediate defect area.

[0043] 7, the wiping media extends from rolling tool 710a to 710b such that wiping media 720 is unwound from one rolling tool (e.g., 710a), rolled over node 702, and wound onto a receiving tool (e.g., 710b). This cycling of the wiping media allows a supply of new or unsaturated wiping media 720 to contact the workpiece surface and the soiled media 720, and then rolled onto 710b.

[0044] In one embodiment, the system 700 also includes a debris removal tool 722 that can remove a portion of the slurry or debris from the media 720 after the media 720 has been used and before the media 720 is rerolled. The debris removal tool 722 can be, for example, a scraping, brushing, or percussion tool that removes dried and caked slurry. In some embodiments, the wiping medium can be a continuous belt wrapped around both sides of the rolling tools 710a / 710b. In another embodiment, the debris removal tool 722 can be comprised of a more mechanical device, such as an air knife, vacuum, or rinse tool. Such a mechanical tool 722 can effectively remove dried particulate matter.

[0045] 8 shows a schematic diagram of a robotic repair system 800. The robotic repair system 800 can be useful for sanding and polishing defects on a work surface, according to embodiments herein. In some embodiments, the work surface can be a vehicle, such as an automobile, car, truck, boat, plane, helicopter, etc.

[0046] In one embodiment, the robotic repair system 800 has an optical sensor 804 that may be used to identify paint / clearcoat flaws or areas to be repaired. The robotic repair system 800 includes a robotic movement mechanism 808 that may be used to move the end-of-arm assembly to the vicinity of the defective repair area. As shown in FIG. 8, in one embodiment, the robotic repair system 800 includes a controller 830 that controls the movement and sensing of the robotic arm 810 and associated components. However, in some embodiments, it is expressly contemplated that the robotic arm 810 and / or components mounted thereon have their own controllers that receive and execute movement and sensing commands from the controller 830.

[0047] In some embodiments, at the end of the robotic arm 810 is an end-of-arm assembly that can include various tools, for example, as shown in Figures 5-7 and 10-12. However, it is expressly contemplated that in other embodiments, as shown in Figure 8, some components may be located elsewhere on one or more of the driven robotic arms 810.

[0048] A first abrasive tool 842 may be mounted on the robot arm 810. The first abrasive tool, in some embodiments, is coupled to the first end effector 840. In some embodiments, a second abrasive tool 848 is mounted on the robot arm 810. The second tool 848 may be coupled to the second end effector 846. A fluid removal mechanism 860 may be mounted on the robot arm 810. However, in some embodiments, it is expressly contemplated that some of these components may be on more than one robot arm 810. For example, the first robot arm 810 may support a first abrasive tool 842, e.g., a sanding robot having a sanding tool, and the second robot arm 810 may support a second abrasive tool, e.g., a polishing robot having a polishing tool.

[0049] In one embodiment, the robot arm 810 is moved into position by an arm movement mechanism 816. The polishing tools 842, 848 and fluid removal system 860 may also be moved into position by the arm movement mechanism 816 in one embodiment, or each may have their own movement mechanisms that move them into position on the workpiece surface.

[0050] A force control unit 812 may also be located on the robot arm 810 to control the interaction between the robot arm 810, the end effector system, and the workpiece surface.

[0051] In some embodiments, an air line 814 and a fluid dispenser 826 feed from the robotic arm 810 to the end effector system to provide the necessary air and fluid supplies to operate the first tool 842 and the second tool 848.

[0052] In one embodiment, the fluid removal tool 850 is also coupled to the force control unit 812. The fluid removal tool 850 may be, for example, a fabric-based wiping medium, an air knife, a vacuum system, or another suitable tool. However, in some embodiments, it is contemplated that the fluid removal tool 850 is coupled to a force control unit separate from that used for tool 842 or tool 848. It is also contemplated that in other embodiments, the fluid removal tool 850 is a passive tool that does not have an associated force control unit. In some embodiments, the fluid removal tool 850 is mounted in a fixed position on the robot arm 810. In some embodiments, a fastener 852 may be used to secure the fluid removal tool 850 in a position that allows for passive wiping. The fastener 852 may be extendable or coupled to the force control unit 812 in some embodiments to facilitate semi-passive wiping.

[0053] The robotic arm 810 may also include a fluid removal compliance device 856 that may provide force compliance for the fluid removal tool 856. The fluid removal compliance device 856 may be a passive compliance device, such as a flexible or compressible material that forces the wiping medium toward the work surface. In other embodiments, the fluid removal compliance device 856 is a mechanical device, such as a mechanical spring or a pneumatic air cylinder.

[0054] In some embodiments, the fluid removal tool 850 may be moved through space using a fluid removal movement mechanism 854. The movement mechanism 854 will control variables such as pitch, tilt, and yaw of the active wiping motion of the fluid removal tool 850. The robotic trajectory generator 809 generates a trajectory for the fluid removal tool 850 and / or the fluid removal tracking device 856 such that an outer portion of a surface area of ​​the fluid removal tool 850 encounters an area of ​​the surface having fluid.

[0055] In some embodiments, the fluid removal tool 850 may work in conjunction with a fluid removal force control unit 858. The force control unit 858 may maintain an appropriate force or pressure between the fluid removal tool 850 and the workpiece. The fluid removal force control unit 858 may be attached to the robot arm 810 and may provide signals or controls to the fluid removal tool 850 via fasteners 852. In other embodiments, the pressure or tension on the workpiece surface is regulated by a fluid removal compliance device 856.

[0056] In some embodiments, the fluid removal tool 850 may work in conjunction with a fluid removal reconditioning device 860. The reconditioning device 860 may be a vacuum, brush, or scraping tool used to remove particulate matter, debris, liquid, or slurry from the wiping media of the fluid removal tool 850. The reconditioning device 860 may also be a heat source, air source, or other water vaporizer. For example, the fluid removal tool 850 may be placed near a heat lamp or fan between wiping operations. The reconditioning device 860 may help provide an effective wiping media with suitable absorbency for cleaning the workpiece surface more than once.

[0057] In another embodiment, the fluid removal tool 850 may include a replaceable component, such as a new absorbent pad, when the old absorbent pad becomes saturated with fluid or debris. The fluid removal replacement mechanism 862 can facilitate replacement of the wiping media fluid removal tool 850. In some embodiments, the replacement mechanism 862 is a release clip, button, or hook and loop system used to quickly replace saturated or depleted wiping media.

[0058] However, in some embodiments, the fluid removal tool 850 is intended to operate at a substantially steady state such that a single fluid removal tool can operate over a large number of wiping operations, e.g., more than 10, more than 50, or more than 100 operations, before replacement is required. This can be achieved by operating the robotic system 800 such that the fluid removal tool expels the same amount of fluid as it absorbs during a wiping operation. Fluid may be removed from the fluid removal tool 850 using a secondary fluid removal tool 851, such as, for example, a heat source, air flow source, or vacuum source applied either during the wiping operation or between subsequent wiping operations. Fluid may also be removed by heat caused by friction of the fluid removal tool 850 against the surface. In addition, fluid uptake may be controlled by the robot trajectory generator 809 moving the fluid removal tool 850 such that the fluid is uptaken in an outer region of the fluid removal tool 850. In the outer regions, the higher rotational speed creates more friction and therefore more heat, which helps the trapped fluid to escape by evaporation or centrifugal force.

[0059] Figure 9 illustrates a method for repairing a defective area on a work surface, according to an embodiment of the present invention. Method 900 may be useful with any of the systems described with respect to Figures 5-10. However, method 500 may also be implemented with another suitable robotic repair system.

[0060] In block 910, the surface repair system images the workpiece and identifies and locates defects, e.g., scratches on the paint or clear coat surface, for repair, as shown in block 912. The driven robot arm then locates a general position of the robot arm and positions the end-of-arm system over the defective area to allow tool access to the workpiece, as shown in block 914. Detecting defects may also include other detection and location methods or processes, as shown in block 916. Imaging the surface and moving the robot into position may be on a series of sensors and motion controllers as described in FIG.

[0061] At block 920, the robotic repair system places a first tool in position to repair the detected defects. This may include moving a sanding tool into contact with the surface. The workpiece is processed using the first tool. Processing the workpiece surface often includes dispensing a fluid 922 used in the processing, such as water, or an abrasive or polishing solution. Sanding the surface often forms a particulate slurry or suspension on the work surface.

[0062] At block 930, fluid is removed from the work surface. Fluid removal may occur as the end-of-arm assembly transitions from the first position to the second position. The fluid removal step is intended to clean the work surface prior to the second polishing step. In some embodiments, this fluid removal step may be accomplished using passive contact, such as dragging a cloth or sponge across the surface, as shown in block 932. In some embodiments, fluid removal includes semi-passive contact, such as a moving part that applies a force or moves a sponge or cloth across the work surface, as shown in block 934. In some embodiments, fluid removal includes active contact, such as a vacuum, air knife, or other active wiping mechanism, as shown in block 936.

[0063] A passive fluid removal process may allow the fluid removal tool to eventually contact or interact with the workpiece surface as the end-of-arm assembly robot translates without additional input or movement from a force or motion controller. In some embodiments, the fluid removal tool may be fixed in a determined position based on the robot rotation technique to facilitate such contact. A partially passive fluid removal process may occur as the end-of-arm assembly robot translates, but may require additional input or movement from a force or motion controller.

[0064] In some methods, the robot will first process the workpiece at a first location, e.g., block 940, and then transition to a second robot location, e.g., block 940, with an intermediate fluid removal step.

[0065] In some embodiments, removing fluid from the work surface may include the fluid removal tool operating at or near a steady state condition with respect to moisture uptake. If a steady state can be achieved with respect to entrained water in the fluid removal tool, the useful life of replaceable components such as pads, brushes, or other absorbent materials will be significantly extended. The pad may then be replaced depending on the load of polishing material and abrasive debris, or wear of the pad itself. If instead the pad had to be replaced based on entrained fluid, the pad would have to be replaced every few cycles. The robot's operating parameters can be selected, such as the lateral and rotational movement speeds of the fluid removal tool, the force applied to the fluid removal tool, the amount of fluid dispensed, and the use of secondary fluid removal tools such as heat, air, or vacuum sources.

[0066] It is expressly contemplated that in some embodiments, steady state or near steady state may be achieved for polishing as well: the water in the polishing material evaporates leaving behind polishing particles that then dry and become loose and can be removed by tapping the pad, letting the pad spin freely, or may flake off as the pad moves or spins against the surface.

[0067] At block 940, the robotic repair unit may be in a second position such that a second tool interacts with the workpiece. For example, after a sanding process, the work surface may need to be polished, as shown in block 942. In some embodiments, it may also be useful to image the work surface after the fluid has been removed, as shown in block 946. The second position may also facilitate changing out the wiping media, for example replacing saturated wiping media with a new or less saturated replacement, as shown in block 944. Other operations that may be performed by the robotic repair unit are also envisioned, as shown in block 948.

[0068] The fluid removal tool of the present invention may be a sponge or cloth-like material that functions as a wiping medium. A wiping medium with high absorption capacity should be selected to maximize the efficiency of removing slurry from the work surface. The wiping medium should also have a high saturation capacity to prevent sloppy or inefficient fluid removal. Wiping media made from channeled or woven materials may provide improved slurry capture, resulting in a cleaner work surface with fewer striations. The wiping medium may be fixed to the end effector in conjunction with a force control device, or may be fixed with pneumatic, spring, or other compliant systems to ensure ideal pressure placement on the work surface.

[0069] 10A-10C are examples of possible wiping media used as fluid removal tools. The media 1000 shown in FIG. 10A-1 has a surface that includes raised bumps that form liner channels, as shown by lines 1002. Wiping the media 1000 across a surface in a single motion may leave a line of material due to the movement of the channels 1002 across the surface. Alternatively, it may be possible to rotate the media 1000 so that it is pulled along the surface at an angle to the channels 1002, as shown by arrow 1010. However, other angles are expressly contemplated, and anything between 5° and 175° may be suitable, for example. The performance of the media 1000 can be seen in FIG. 10A-4. Two orientations of the media 1000 were tested, including, for example, a straight orientation shown in FIG. 10A-2, and an angled orientation shown in FIG. 10A-3. As shown in Figure 10A-4, both the straight and angled orientations removed some of the slurry mixture, but the angled orientation performed better. In the straight orientation, slurry material trapped within the channels 1002 of the media 1000 left streaks.

[0070] 10B shows wiping medium 1020. Media 1020 includes rows of raised portions 1022 that are offset from adjacent portions such that there are no channels. Wiping medium 1020 may be preferred over media 1000 because it may leave less residue behind.

[0071] FIG. 10C shows wiping medium 1040, which shows wiping material without distinct channels or raised portions. Wiping media 1000, 1020, and 1030 are all microfiber materials. However, similar results may be seen with other fabrics. However, microfiber materials may be preferred because they have higher absorbency than other fibers. As used herein, microfiber refers to fine synthetic woven fibers, typically with fibers finer than 1 denier. Microfibers can be made from polyamide, polyester, polypropylene, or another suitable material. Microfibers may be extruded and mechanically or chemically treated to break them into finer particles, which may generate a positive charge within the fiber. The fibers are then woven into a plain weave or loop weave. Loop woven microfibers may be preferred because the fabric web can better remove and absorb debris and fluids.

[0072] Microfiber materials are typically rated in grams per square meter (GSM), which is a measure of density, but is often referred to as weight. In some embodiments herein, the microfiber wiping medium is at least 200 GSM, or at least 250 GSM, or at least 300 GSM, or at least 350 GSM, at least 400 GSM, at least 500 GSM, or even denser. Figures 10A and 10B show a lower pile weave than Figure 10C-1, which shows a higher pile weave 1030. As shown in Figure 10C-2, the higher pile weave fabric 1030 shows improved wiping when used in either a straight or angled orientation.

[0073] However, for purposes of understanding, while straight or angled orientations are described, it is expressly contemplated that other motions may be possible, for example, a tool capable of rotational, orbital, or random orbital motion may be coupled to the wiping medium.

[0074] Improved wiping quality is seen with increasing available surface area, which is related to increased pile or length of fibers in the loop portion of the loop weave. In addition, the amount of wiping work increases with increasing available surface area. For example, wiping media 1000 was saturated after 5 sanding repair operations.

[0075] However, in a given work shift, as many as 2000 repair operations may be performed, and it would be desirable to have a wiping solution that is not burdensome to replace and can last for a significant portion of the work shift.

[0076] One possible solution is to increase the size of the wiping media. For example, human operators often use buffing pads that are much larger than the sanding tools used by the robotic repair units. However, smaller wiping units are preferred because the defects to be repaired may be on uneven surfaces. The wiping unit should be able to penetrate the unevenness of the vehicle body. It is preferred to have a wiping unit that has a similar footprint to the sanding or polishing tools used by the robotic repair units.

[0077] It has been discovered that rotating the wiping tool while in contact with the work surface generates sufficient heat to allow at least a portion of the moisture being removed to evaporate. Additionally, it has been found that the cycle time required to remove fluid is significantly reduced when the wipe is rotated as compared to simply translating over the slurry. Thus, it has been found that the wiping area of ​​the wiping tool can be smaller and the tool will still last for a significant number of wiping runs without becoming completely saturated. For example, by generating sufficient heat to cause evaporation of the entrained fluid, it is possible to significantly increase the amount of slurry that can be removed from a surface by a single wiping tool, thereby extending the number of sanding runs that can be completed. For example, it may even be possible to approach steady state operation with respect to liquid uptake by evaporating nearly as much or as little entrained liquid as is absorbed during operation.

[0078] 11A and 11B show a wiping system according to embodiments herein. The wiping system 1100 includes an absorbent wiping unit 1110 coupled to a drive unit 1102. The drive unit 1102 may be capable of moving in a z-axis direction, toward or away from a work surface. The z-axis movement may be achieved using an electric or pneumatic motor to move the wiping unit toward or away from a robot arm. The drive unit 1102 may be coupled to a compliant unit 1104, which may be directly coupled to the wiping unit 1110. In some embodiments, the compliant unit 1104 may be a back-up pad or may be a compliant interface pad, as shown in FIG. 11A. The drive unit 1102 may also be capable of rotating, for example, as shown by arrow 1108.

[0079] The absorbent wiping unit 1110 can be characterized as having a backing 1118 with a plurality of protrusions 1106. The backing 1118 may have a width substantially the same as the width of the compliant unit 1104, as shown in FIG. 11A. As shown in FIG. 11A, in some embodiments, the wiping unit 1110 is a microchenille wipe made up of several microfiber strands woven to form protrusions 1112, each of which has a length 1116 and a diameter 1114. As shown in FIG. 11A, the length 1116 is greater than the diameter 1114. In some embodiments, the length 1116 may be less than 10 times the diameter 1114. However, as shown in FIG. 11B, in some embodiments, the length 1116 is greater than 10 times the diameter 1114. The surface area available for use with the wiping unit 1110 is much greater than when using wiping media 1000 , 1020 or 1030 coupled to a compliant unit 1104 .

[0080] When tested, in comparison to wiping media 1000 and 1030, wiping unit 1110 lasted through 200 debris remediation sessions without saturating.

[0081] In addition to the increased surface area, the wiping system 1100 can increase the number of successive repair runs that can be performed without saturation due to rotation and heat generation in two other ways.

[0082] In some embodiments, the system 1100 can move in the z-direction such that the protrusions 1112 are pushed into the surface by the compliant units 1104 while the drive unit 1102 rotates. This creates friction, which can provide enough heat to evaporate some of the absorbed liquid. Additionally, rotation can continue while the drive unit 1102 is lifted away from the work surface, which can cause some liquid or debris to be expelled from the protrusions 1112.

[0083] It may also be possible to increase the frequency of servicing by periodically brushing, knocking, or otherwise removing debris from the wiping unit 1110, for example, by brushing the protrusions 1112 against a rough surface, a bristle brush, or another surface.

[0084] In some embodiments, it may be possible to reach or approach a steady state operation where substantially the same amount of fluid is taken up as is evaporated or knocked off during each new wipe. Achieving or approaching a steady state may refer to only water uptake such that the same amount of water that was absorbed as part of the slurry is released due to evaporation or knocked off the wiping unit 1110. In a water steady state operation, debris may still accumulate on the surface of the wiping unit 1110. In other embodiments, while a steady state is not reached, the wiping unit 1110 lasts for more than 100 sanding operations, or more than 200 sanding operations, or more than 300 sanding operations, or more than 500 sanding operations, or more than 1000 sanding operations.

[0085] In some embodiments, the effectiveness of the wiping unit 1110 can be measured by the amount of slurry or debris removed from the work surface before the wiping unit 1110 becomes saturated or no longer adequately removes debris from the work surface.

[0086] When the wiping unit 1110 becomes sufficiently saturated with debris, the wiping unit may be replaced or reconditioned. Replacement may include removing the wiping unit 1110, for example, by detaching it from the compliant pad 1104, so that a new or reconditioned wiping unit 1110 can be installed. For example, a hook and loop attachment may be used between the wiping unit backing 1118 and the compliant unit 1104.

[0087] In some embodiments, reconditioning the wiping unit 1110 may include putting it through a cleaning or drying cycle after removal from the compliant pad 1104. However, in some embodiments, at least some reconditioning can occur while the wiping unit 1110 is coupled to the drive unit 1102, for example, by engaging a rough or bristled surface to remove dried debris from the surface of the protrusions 1112.

[0088] 11B shows another embodiment of a wiping assembly 1150 in which a wiping unit 1160 is attached to a drive arm 1152. The wiping unit 1160 has a backing with a width 1162 dimensioned similarly to the width at the point where the wiping unit 1160 couples to the drive arm 1152. The drive arm 1152 may be capable of moving the wiping unit 1160 in the z-direction, for example, downward toward the surface and upward away from the surface. The drive arm 1152 may also be capable of spinning, for example, as shown by arrow 1168.

[0089] The wiping unit 1160 includes a plurality of strands extending from a backing, each strand having a strand length 1164. Figure 11B shows an embodiment in which the strands have a length 1168 that is more than ten times the dimension of the strand thickness.

[0090] Although wiping systems 1100 and 1150 are shown alone in Figures 11A and 11B, it is expressly contemplated that in some embodiments, one or more tools or fluid dispensers are mounted on the same driven robotic system as wiping systems 1100, 1150.

[0091] As mentioned above, the wiping system 1100, 1150 is advantageously located on the drive robot arm so as not to add significant time to the repair process. Thus, in some embodiments, it may be advantageous to place the wiping system 1100, 1150 on the same drive robot as either the sanding tool or the polishing tool. In one embodiment, the wiping system 1100, 1150 is aligned with the polishing tool adjacent to the tool, for example on a rail system, so that the wiping system can be moved into position without significant movement of the drive arm. In another embodiment, the wiping system is adjacent to the polishing tool, but the drive arm must move linearly to place the wiping system in position over the sanded or polished area. In some embodiments, the wiping system may share a force control unit with the polishing tool. In some embodiments, the wiping system may share a motion control system with the polishing tool.

[0092] As mentioned above, in some embodiments, the fluid removal system is an active fluid removal system, e.g., a vacuum. However, it has been found that when a vacuum is applied, the water of the slurry is easily removed, leaving behind a film of debris that is well-adhered to the paint surface. The film of debris can be removed by pushing it aside, but any method that may cause scratches on the surface should not be used to push the debris aside. Instead, the slurry debris can be easily removed if the vacuum is delivered through a bristle-like surface, with bristles that have a low risk of scratching the paint surface. Figures 12A-12D show diagrams of a vacuum attachment that may be used in accordance with embodiments herein. Figure 12A shows a side view of a brush 1200 having a vacuum attachment side 1202 and a surface contacting side 1204 that contacts a surface 1210. Bristles 1208 extend from a backing over a length 1206. As the brush 1200 moves across the surface 1210 , the bristles 1208 remove debris that has adhered to the surface 1210 .

[0093] FIG. 12B shows an underside view of the brush 1200, illustrating a number of vacuum holes 1220 through which a vacuum can be drawn.

[0094] 12C shows a side view of the brush 1250 with multiple bristles 1260 and vacuum holes 1270 extending through the brush 1250. The bristles 1260 are much closer together than the bristles 1208. The bristles 1260, 1208 are made from a material that can bend, flex, or compress in response to a force without scratching the surface in some embodiments. Silicone, compliant polymers or plastics, hair, or another suitable material may be used for the bristles 1208, 1260.

[0095] A wiping system for a robotic repair unit is presented that includes a driven robot arm having a motor, a connection mechanism coupled to the driven robot arm, and a wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The driven robot arm is driven by the motor to move the wiping medium. The driven robot arm is configured to move the wiping medium toward or away from a work surface. The drive arm is configured to urge the wiping medium toward the work surface during a wiping operation. During the wiping operation, the wiping medium is driven against the surface by the wiping motor.

[0096] The system may be implemented such that each of the plurality of features has a feature height and a feature thickness, the feature height being greater than the thickness of the base layer.

[0097] The system may be implemented such that the feature height is at least twice the feature thickness.

[0098] The system may be implemented such that the feature height is less than 10 times the feature thickness.

[0099] The system may be implemented such that the wiping medium comprises microfibers.

[0100] The system may be implemented such that the wiping medium is a chenille microfiber.

[0101] The system may be implemented to include a compliant layer between the wiping media and the driven robot arm.

[0102] The system may be implemented such that the wiping motor moves the wiping media in a reciprocating or oscillatory motion pattern.

[0103] The system may be implemented such that the wiping motor is separate from the motor.

[0104] The system may be implemented such that the wiping motor drives the wiping media at a first speed during a wiping operation and spins the wiping media at a second speed as the wiping media moves away from or towards the work surface, the second speed being greater than the first speed.

[0105] The system may be implemented such that the connection mechanism comprises a hook and loop system.

[0106] The system may be implemented to include a force control unit.

[0107] The system may be implemented such that the wiping motor moves the wiping media in a rotary motion pattern.

[0108] The system may be implemented such that the wiping motor moves the wiping media in an orbital motion pattern.

[0109] The system may be implemented such that the wiping motor moves the wiping media in a random orbital motion pattern.

[0110] The system may be implemented such that the wiping motor is an electric motor.

[0111] The system may be implemented such that the wiping motor is a pneumatic motor.

[0112] The system may be implemented such that after 10 sanding passes, the wiping media is non-saturated.

[0113] The system may be implemented such that the wiping media is non-saturated after 50 sanding passes.

[0114] The system may be implemented such that the wiping media is non-saturated after 200 sanding passes.

[0115] The system may be implemented such that the wiping media is non-saturated after 1000 sanding operations.

[0116] The system may be implemented such that after 50 sanding passes, the wiping media removes 75% of the slurry.

[0117] The system may be implemented such that after 100 sanding passes, the wiping media removes 85% of the slurry.

[0118] A wiping system for a robotic repair unit is presented that includes a driven robot arm having a motor, a connection mechanism coupled to the driven robot arm, and a wiping medium coupled to the connection mechanism. The wiping medium comprises a base layer and a plurality of features extending from the base layer. The driven robot arm is driven by the motor to move the wiping medium. Each of the plurality of features has a feature height and a feature thickness. The feature height is greater than the thickness of the base layer. The feature height is at least two times the feature thickness, or the feature height is less than ten times the feature thickness.

[0119] A wiping system for a robotic repair unit is presented that includes a drive robot arm having a motor, a connection mechanism coupled to the drive robot arm, a compliant layer between the wiping medium and the drive robot arm, and the wiping medium coupled to the connection mechanism. The wiping medium includes a base layer and a plurality of features extending from the base layer. The drive robot arm is driven by the motor to move the wiping medium.

[0120] A robotic paint repair system is presented that includes a force control unit, a first tool system with a first end effector coupled to a first tool configured to contact a workpiece, a second tool system with a second end effector coupled to a second tool configured to contact a workpiece, and a fluid removal tool including a wiping medium, the fluid removal tool being coupled to a driven robot arm. The fluid removal tool is configured to remove fluid from the workpiece. In a first state, the first tool is in a position to contact an object surface to prepare the object surface, in a second state, the second tool is in a position to contact the workpiece to prepare the workpiece, and in a third state, the fluid removal tool is in a position to contact the workpiece. The driven robot arm is configured to move the wiping medium toward or away from the work surface. The driven arm is configured to press the wiping medium toward the work surface during a wiping operation. During the wiping operation, the wiping medium is driven against the surface by a wiping motor.

[0121] The system may be implemented such that the first tool and the second tool are mounted to a single robotic repair unit.

[0122] The system may be implemented such that the first tool and the fluid removal tool are mounted to a single robotic repair unit.

[0123] The system may be implemented such that the first tool and the second tool are positioned at least 90 degrees apart on the driven robot arm.

[0124] The system may be implemented such that the fluid removal tool is mounted vertically to the first tool and the second tool.

[0125] The system may be implemented such that the wiping medium comprises a water-absorbent material.

[0126] The system may be implemented such that the fluid removal tool includes a vacuum.

[0127] The system may be implemented such that the fluid removal tool comprises an air knife.

[0128] The system may be implemented such that the wiping medium comprises microfibers.

[0129] The system may be implemented such that the wiping medium comprises chenille microfiber.

[0130] The system may be implemented such that the wiping medium has an attachment diameter that is attached to the robotic repair unit, and a plurality of absorbent units extend away from an axis defined by the attachment diameter, each of the absorbent units including a plurality of microfiber strands.

[0131] The system may be implemented such that the microfiber is at least 300 gpsm.

[0132] The system may be implemented such that the wiping motor moves the wiping media in a reciprocating or oscillatory motion pattern.

[0133] The system may be implemented such that the fluid removal tool includes a compliant device.

[0134] The system may be implemented such that the compliant device is a compliant material.

[0135] The system may be implemented such that the wiping motor drives the wiping medium at a first speed during a wiping operation and spins the wiping medium at a second speed as the wiping medium moves away from or towards the work surface, the second speed being faster than the first speed.

[0136] The system may be implemented such that after 10 sanding passes, the wiping media removes at least 70% of the slurry from the surface.

[0137] The system may be implemented such that after 100 sanding passes, the wiping media removes at least 70% of the slurry from the surface.

[0138] The system may be implemented such that after 200 sanding passes, the wiping media removes at least 70% of the slurry from the surface.

[0139] The system may be implemented such that the fluid removal tool is fastened directly to the first end effector.

[0140] The system may be implemented such that the fluid removal tool is coupled to the force control unit.

[0141] The system may be implemented such that the first tool is coupled to the force control unit.

[0142] The system may be implemented such that the fluid removal tool is fastened to the end effector system using a compliant fastener.

[0143] The system may be implemented such that the wiping medium comprises a sponge.

[0144] The system may be implemented such that the wiping medium is a fabric.

[0145] The system may be implemented such that the wiping medium is at an angle relative to the workpiece surface.

[0146] The system may be implemented such that the fabric comprises a plurality of raised portions arranged in rows, the rows forming a plurality of channels.

[0147] The system may be implemented such that the wiping medium is positioned such that the channels are at an angle to the wiping direction.

[0148] The system may be implemented such that the fabric comprises a plurality of raised portions, a first row of the raised portions being offset from a second row of the raised portions, such that the fabric is free of channels.

[0149] The system may be implemented such that the fabric is substantially free of channels.

[0150] The system may be implemented such that the wiping media is removable from the robotic repair system using a connection mechanism.

[0151] The system may be implemented such that the wiping medium is a single-use wiping medium that includes a connection mechanism for connecting to a fluid removal tool. The single-use wiping medium becomes saturated after one wiping operation.

[0152] The system may be implemented such that the connection mechanism is a fastener.

[0153] The system may be implemented such that the connection mechanism is compliant.

[0154] The system may be implemented such that the connection mechanism comprises a hook and loop system.

[0155] The system may be implemented such that the fluid removal tool comprises a roll-to-roll system, where the wiping medium is unwound from a first roller and wound onto a second roller.

[0156] The system may be implemented such that the wiping medium is a belt stretched between a first roller and a second roller, the first roller being spaced apart from the second roller.

[0157] The system may be implemented such that the wiping medium is indexed after each use such that a first portion of the wiping medium is unwound from a first roller and a second portion is wound onto a second roller, the first portion having a first area and the second portion having a second area, the first and second areas being substantially similar in size.

[0158] The system may be implemented such that the wiping medium is under tension.

[0159] The system may be implemented such that tension is applied by a tension rod.

[0160] The system may be implemented such that the tension rods are compliant.

[0161] The system may be implemented such that the roll-to-roll system includes a debris removal mechanism that removes debris from the second portion.

[0162] The system may be implemented such that the roll-to-roll system includes a debris removal mechanism that removes debris from the second portion.

[0163] The system may be implemented to also include an air flow directed toward the second portion.

[0164] The system may be implemented such that the debris removal mechanism comprises a pin, a scraper, or a percussion tool.

[0165] The system may be implemented such that the fluid removal tool is fixed in a position that allows access to the workpiece surface as the system transitions from a first tool to a second tool.

[0166] The system may also include a sensor configured to detect an operational status of the defect repair system, and a control circuit that receives signals from the sensor and processes the signals to generate status information for the defect repair system.

[0167] The system may be implemented such that the defect repair system is mounted on a driven robotic arm.

[0168] The system may be implemented such that the compliant fastener comprises a pneumatic cylinder, a linear servo drive, a pneumatic force control, a hydraulic cylinder, a rubber pad, or a spring.

[0169] A robotic paint repair system is presented that includes a force control unit, a first tool system with a first end effector coupled to a first tool configured to contact a workpiece, a second tool system with a second end effector coupled to a second tool configured to contact the workpiece, and a fluid removal tool configured to remove fluid from the workpiece. The fluid removal tool is directly fastened to the first end effector. In a first state, the first tool is in a position to contact an object surface to prepare the object surface, in a second state, the second tool is in a position to contact the workpiece to prepare the workpiece, and in a third state, the fluid removal tool is in a position to contact the workpiece.

[0170] A robotic paint repair system is presented that includes a force control unit, a first tool system with a first end effector coupled to a first tool configured to contact a workpiece, a second tool system with a second end effector coupled to a second tool configured to contact the workpiece, and a fluid removal tool configured to remove fluid from the workpiece, the fluid removal tool being coupled to the force control unit, where in a first state, the first tool is in a position to contact an object surface to prepare the object surface, in a second state, the second tool is in a position to contact the workpiece to prepare the workpiece, and in a third state, the fluid removal tool is in a position to contact the workpiece.

[0171] A method of repairing a workpiece is presented that includes contacting the workpiece using a first tool. The first tool is attached to a first end effector aligned to treat a surface of the workpiece. The first end effector is coupled to a first force control unit mounted on an end of an arm of a robotic repair unit, and the first tool is an abrasive tool. The method also includes removing fluid from the workpiece using a fluid removal tool coupled to the robotic repair unit. The fluid removal tool is a wiping medium, and the wiping medium includes an absorbent material. The method also includes contacting the workpiece using a second tool. The second tool is a second abrasive tool.

[0172] The method may be implemented such that the fluid removal tool is actuated during end-of-arm movement of the robotic repair unit.

[0173] The method may be implemented such that the first tool is a sanding tool.

[0174] The method may be implemented such that the second tool is a polishing tool.

[0175] The method may be implemented such that the first tool and the second tool are both mounted on an end of an arm of a robotic repair unit, the first tool and the second tool being mounted at least 90 degrees apart.

[0176] The method may be implemented such that the fluid removal tool is vertically mounted to one of the first tool and the second tool.

[0177] The method may be implemented such that the wiping medium comprises a backing and a plurality of protrusions extending from the backing.

[0178] The method may be implemented such that each of the plurality of protrusions comprises a strand of fiber.

[0179] The method may be implemented such that the absorbent material is a microfiber.

[0180] The method may be implemented such that the absorbent material is a chenille microfiber.

[0181] The method may be implemented such that the microfiber is at least 200 gpsm.

[0182] The method may be implemented such that the microfiber is at least 300 gpsm.

[0183] The method may be implemented such that the microfiber is at least 400 gpsm.

[0184] The method may be implemented such that the microfiber is at least 500 gpsm.

[0185] The method may be implemented such that the fluid removal tool is a vacuum.

[0186] The method may also be implemented to include a debris removal attachment.

[0187] The method may be implemented such that the debris removal attachment includes bristles.

[0188] The method may be implemented wherein the fluid removal tool comprises an air knife.

[0189] The method may be implemented such that the fluid removal tool is coupled to a fluid removal force control unit.

[0190] The method may be implemented such that the fluid removal tool is coupled to the motion controller.

[0191] The method may be implemented such that a motion controller moves the fluid removal tool toward or away from the workpiece.

[0192] The method may be implemented such that the motion controller spins the fluid removal tool.

[0193] The method may be implemented such that the wiping medium is a sponge.

[0194] The method may be implemented such that the wiping medium is a fabric having a plurality of channels.

[0195] The method may be implemented such that the wiping medium comprises a plurality of channels defined by raised portions, and the wiping medium is inclined relative to the workpiece surface, such that the channels are inclined relative to the wiping direction.

[0196] The method may be implemented such that the first channel is offset from the second channel.

[0197] The method may be implemented such that the wiping medium is a cloth without ridges.

[0198] The method may be implemented such that the wiping medium is removable.

[0199] The method may be implemented such that the wiping medium is a single-use wiping medium that includes a connection mechanism for connecting to a fluid removal tool.

[0200] The method may be implemented such that the connection mechanism is a fastener.

[0201] The method may be implemented such that the connection mechanism is compliant.

[0202] The method may be implemented such that the connection mechanism comprises a hook and loop system.

[0203] The method may be implemented such that the fluid removal tool includes a roll-to-roll system, where the wiping medium is unwound from a first roll and wound onto a second roll.

[0204] The method may be implemented such that removing fluid from the workpiece includes unwinding a first portion of the wiping medium from a first roller and winding a second portion of the wiping medium onto a second roller, the first portion having a first area and the second portion having a second area, the first area and the second area being substantially similar.

[0205] The method may be implemented to include removing the debris from the second portion.

[0206] The method may be implemented such that removing fluid from the workpiece includes the fluid removal tool passively contacting the workpiece surface as the arm end assembly transitions from a first state in which a first tool is in contact with the workpiece to a second state in which a second tool is in contact with the workpiece.

[0207] The method may be implemented such that removing fluid from the workpiece includes semi-passively contacting the fluid removal tool with the workpiece surface such that a motion controller coupled to the arm end assembly extends the fluid removal tool to a workpiece contacting position when the arm end assembly transitions from a first state in which the first tool is contacting the workpiece and a second state in which the second tool is contacting the workpiece.

[0208] The method may be implemented such that the first tool is fastened to an end-of-arm robot assembly.

[0209] The method may be implemented such that the workpiece is a vehicle.

[0210] The method may be implemented such that the vehicle is a car.

[0211] A fluid removal system mounted to the driven robotic system is presented that includes a first roller mounted to the driven robotic system, a second roller spaced apart from the first roller, a tension rod, and a wiping material configured to be unwound from the first roller and wound over the tension rod onto the second roller, the tension rod being positioned such that a portion of the wiping material contacting the tension rod on a first side contacts a workpiece on a second side.

[0212] The system may be implemented such that the wiping medium is a fabric having multiple channels.

[0213] The system may be implemented such that the textile is a fabric.

[0214] The system may be implemented such that the wiping media is tilted relative to the workpiece surface, such that the channels are misaligned relative to the wiping direction.

[0215] The system may be implemented such that being misaligned includes the channel being angled relative to the wiping direction.

[0216] The system may be implemented such that the first channel is offset from the second channel.

[0217] The system may be implemented such that the first channel is staggered from the second channel.

[0218] The system may be implemented such that the wiping medium is a cloth without ridges.

[0219] The system may be implemented such that there is no separate channel for the wiping medium.

[0220] The system may be implemented such that the fluid removal system comprises a motion controller.

[0221] The system may be implemented such that a motion controller moves a tension rod.

[0222] The system may be implemented such that a motion controller controls the tilt, pitch and yaw of the tension rods.

[0223] A driven robotic repair system is presented that includes a force control unit mounted to the driven robotic repair system and a first tool coupled to a first end effector. The first tool is configured to contact a work surface. The first tool is an abrasive tool. The system also includes a fluid removal system that includes a wiping material and a reconditioning tool that removes a portion of the fluid or dried debris from the wiping material. The fluid removal tool is configured to remove fluid or debris from an area of ​​the work surface, and the fluid removal system is mounted to the driven robotic repair system.

[0224] The system may be implemented such that the fluid removal system comprises a fluid removal tool that contacts the work surface.

[0225] The system may be implemented such that the fluid removal system includes an air delivery device that supplies air to the area.

[0226] The system may be implemented such that the removal system includes a vacuum to draw fluid from the area.

[0227] The system may be implemented such that the fluid removal tool includes a wiping material.

[0228] The system may be implemented such that the fluid removal system includes an absorbent wipe.

[0229] The system may be implemented such that the absorbent wipe is a woven or non-woven fabric.

[0230] The system may be implemented such that the fluid removal system comprises a roll-to-roll system.

[0231] The system may be implemented such that a roll-to-roll system includes a first roller and a second roller, wherein a first portion of the wiping medium is unwound from the first roll and wound onto the second roll.

[0232] The system may be implemented such that the wiping medium is indexed after each use such that a first portion of the wiping medium is unwound from a first roll and a second portion is wound onto a second roll, the first portion having a first area and the second portion having a second area, the first area and the second area being substantially similar in size.

[0233] The system may be implemented such that the wiping medium comprises a belt.

[0234] The system may be implemented to include a fluid dispenser that dispenses fluid over an area.

[0235] The system may be implemented to include a second tool coupled to the second end effector, the second tool configured to contact the work surface.

[0236] The system may be implemented such that the first tool is a sanding tool and the second tool is a polishing tool, and the fluid removal system is configured to remove fluid after the first tool contacts the area and before the second tool contacts the area.

[0237] The system may be implemented such that the first end effector is coupled to a force control unit.

[0238] The system may be implemented such that the second end effector is coupled to the force control unit.

[0239] The system may be implemented such that the fluid removal tool is coupled to the force control unit.

[0240] The system may be implemented such that the region includes a defect and the robotic repair system is configured to repair the defect.

[0241] The system may be implemented such that the first tool is a sanding tool that sands the defect.

[0242] The system may be implemented such that the first tool is a polishing tool that polishes the area.

Claims

1. 1. A wiping system for a robotic repair unit, the wiping system comprising: a driven robot arm having a motor; a connection mechanism coupled to the drive robot arm; a wiping medium coupled to the connection mechanism, A base layer; a wiping medium comprising: a plurality of features extending from the base layer; the drive robot arm is driven by the motor to move the wiping medium; A wiping system, wherein the drive robot arm is configured to move the wiping medium toward or away from a work surface, the drive arm is configured to press the wiping medium toward the work surface during a wiping operation, and during the wiping operation the wiping medium is driven against the surface by a wiping motor.

2. The system of claim 1 , wherein each of the plurality of features has a feature height and a feature thickness, the feature height being greater than a thickness of the base layer.

3. The system of claim 1 or 2, wherein the wiping motor is separate from the motor.

4. The system of any one of claims 1 to 3, wherein the wiping motor drives the wiping medium at a first speed during the wiping operation and spins the wiping medium at a second speed when the wiping medium is moving away from or towards the work surface.

5. 1. A method of repairing a workpiece, the method comprising: contacting the workpiece using a first tool, the first tool mounted on a first end effector aligned to treat a surface of the workpiece, the first end effector coupled to a first force control unit mounted on an end of an arm of a robotic repair unit, the first tool being an abrasive tool; removing fluid from the workpiece using a fluid removal tool coupled to the robotic repair unit, the fluid removal tool being a wiping medium, the wiping medium comprising an absorbent material; contacting the workpiece using a second tool, the second tool being a second abrasive tool.

6. 6. The method of claim 5, wherein the first tool and the second tool are both mounted to the arm end of the robotic repair unit, and the first tool and the second tool are mounted at least 90 degrees apart.

7. The method of claim 5 , wherein the wiping medium is a single-use wiping medium that includes a connection mechanism for connecting to the fluid removal tool.

8. The method of claim 5 , wherein the fluid removal tool comprises a roll-to-roll system, and the wiping medium is unwound from a first roll and wound onto a second roll.

9. 6. The method of claim 5, wherein removing includes contacting a wiping material with a work surface, a force is applied to the wiping material, and the wiping material is moved laterally or rotationally relative to the work surface at a velocity, the force and the velocity being sufficient to cause the wiping media to operate near a steady state with respect to moisture uptake during a wiping cycle.

10. 10. The method of claim 9, wherein the wiping material is moved at a lateral velocity and a rotational velocity, the force, the lateral velocity, and the rotational velocity being sufficient to cause the wiping medium to operate near the steady state.

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