Method and system for painting an object - Patents.com

Abstract

A method and system for robotically painting an object is provided. In one embodiment, the method includes providing a scanner robot mechanism. The scanner robot mechanism includes a 3D scanner, a robot, and at least one processor. The 3D scanner in communication with the at least one processor detects an object and determines an area to be painted. An applicator is held offset from the area of ​​the object by the robot in communication with the at least one processor. The applicator is in fluid communication with a paint source that includes paint. The applicator is moved relative to the area of ​​the object by the robot in communication with the at least one processor while depositing paint from the applicator onto the area of ​​the object.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of all aspects of U.S. Provisional Application No. 63 / 265,939, filed December 23, 2021, the contents of which are incorporated herein by reference in their entirety.

[0002] (Technical field) The technical field relates generally to coating, and more particularly to methods and systems for painting objects using an applicator (e.g., a spray gun or other applicator that applies paint) operably coupled to a robot. [Background technology]

[0003] A paint booth is a structure that provides a ventilated, air-filtered, and temperature-controlled environment in which painting of an object can be carried out. Because painting operations involve the dispensing of paint ingredients, such as solvents and particulate matter, that must not enter the atmosphere in significant quantities, paint booths are necessary to safely carry out such activities. Because of this, the environment within a paint booth is confined and requires a high degree of control and expertise. Trained and experienced personnel are often difficult to find and retain, and specialized personal protective equipment (PPE) is required to work in such hazardous confined spaces. Summary of the Invention [Problem to be solved by the invention]

[0004] It would therefore be desirable to provide a method and system for painting an object that addresses one or more of the problems set forth above. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the following detailed description and the appended claims, taken in conjunction with this background. [Means for solving the problem]

[0005] A method and system for robotically painting an object is provided herein. According to an exemplary embodiment, the method includes providing a scanner robot mechanism. The scanner robot mechanism includes a 3D scanner, a robot, and at least one processor in communication with the 3D scanner and the robot. The method further includes detecting the object with the 3D scanner in communication with the at least one processor. An area of ​​the object to be painted is determined with the 3D scanner in communication with the at least one processor. An applicator is held offset from the area of ​​the object with the robot in communication with the at least one processor. The applicator is in fluid communication with a paint source that includes paint. The method further includes moving the applicator relative to the area of ​​the object with the robot in communication with the at least one processor while depositing paint from the applicator on the area of ​​the object.

[0006] According to an exemplary embodiment, a system includes a scanner robot mechanism. The scanner robot mechanism includes a 3D scanner configured to scan an object, a robot, and at least one processor in communication with the 3D scanner and the robot. The 3D scanner in communication with the at least one processor is cooperatively configured to detect the object and determine an area of ​​the object to be painted. The system further includes an applicator configured to be in fluid communication with a paint source including paint. The robot in communication with the at least one processor is cooperatively configured to hold the applicator offset from the area of ​​the object and move the applicator relative to the area of ​​the object while depositing paint from the applicator on the area of ​​the object.

[0007] Various embodiments are now described in conjunction with the following drawings, in which like numerals refer to like elements and in which: [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a block diagram of a method for robotically painting an object in accordance with an illustrative embodiment.

[0009] [Diagram 2] FIG. 2 is a perspective view of an applicator configured as a printhead in accordance with an exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The following detailed description is merely exemplary in nature and is not intended to limit the various embodiments or their application and uses. Further, there is no intention to be bound by any of the preceding background or any theory presented in the following detailed description.

[0011] The term "overlying" as used herein means that the overlying material can be physically in contact with the underlying substrate or layer, or the overlying material can be physically separated from the underlying substrate or layer by an intervening layer, such as an overlying clear coat that can be separated from the underlying substrate or layer (e.g., a primer layer) by a base coat. It is understood that components or objects can be rotated or moved, so a reference to a component, object, or article (layer) being over another component, object, or article (layer) refers to a particular orientation, with the understanding that the actual component, object, or article (layer) can be rotated in a different orientation.

[0012] Various embodiments contemplated herein relate to methods and systems for robotically painting an object. With reference to Figure 1, a method 100 for robotically painting an object is provided according to an exemplary embodiment. The object may be a part, a component such as a vehicle body or trim panel (e.g., an exterior or interior body or trim panel) that may be freestanding, attached to a fixture, or attached to a vehicle, or an assembly of components, such as a vehicle, a portion thereof, or the like.

[0013] In an exemplary embodiment, method 100 includes providing a paint booth (STEP 102). The paint booth is configured, for example, as a structure that provides a ventilated, air filtered, and temperature controlled environment in which painting of objects can be performed. The structure includes openings or doors that allow various objects, components, parts, materials, articles, and / or the like to be moved into and out of the paint booth as needed or otherwise desired, as well as allowing personnel to enter and exit the booth.

[0014] A scanner robot mechanism is provided (STEP 104). The scanner robot mechanism includes a 3D scanner, a robot, and at least one processor in communication with the 3D scanner and the robot.

[0015] The 3D scanner is configured to scan an object and generate data corresponding to a surface (e.g., surface data) and / or a 3D shape of the object (e.g., part or all of the object). In an exemplary embodiment, at least one processor instructs the 3D scanner to scan the object to generate data. As described in more detail below, the data is communicated to the at least one processor for processing to determine the 3D shape of the surface, an area or portion of the surface, and / or the object and / or identify the object. In an exemplary embodiment, the 3D scanner is a non-contact scanner, such as, for example, an ultra-wideband (UWB) scanner, a camera scanner, a time-of-flight (TOF) camera, a sonic scanner, a laser scanner, and a light detection and ranging laser (LiDAR) scanner. In one example, the 3D scanner generates a point cloud as data corresponding to the 3D shape of an area of ​​the object. In an alternative embodiment, the 3D scanner is a contact scanner, such as, for example, a probe that physically contacts a surface along a grid pattern and generates wireframe data corresponding to the surface and / or the 3D shape of the object. In an exemplary embodiment, the 3D scanner is a combination of a non-contact scanner and a contact scanner.

[0016] In an exemplary embodiment, the robot includes a base and an arm disposed on the base for movement along multiple axes, the robot may be, for example, a 3-axis, 4-axis, 5-axis, 6-axis, or 7-axis robot.

[0017] In an exemplary embodiment, the at least one processor is part of a computer. The computer can be used as a device to implement the techniques and methods described herein. The computer can include input devices such as a keyboard, a mouse, an electronic communication device such as a modem, or various other communication devices. The input devices communicate with at least one processor (processing unit) and / or memory of the computer, and the processing unit and memory communicate with each other. A wide variety of processing unit and memory embodiments are known to those skilled in the art. The computer also includes an output device. Other exemplary embodiments of the output device include a modem, a printer, or other components known to those skilled in the art. The methods and techniques described below can be implemented on a computer.

[0018] The computer readable medium embodies a computer program, which may include one or more algorithms, that instructs a computer to perform the methods and techniques described below. The computer readable medium can be an SD card, a USB storage medium, a floppy disk, a CD-ROM, a DVD, a hard drive, or other device that is readable by a computer and includes a memory for storing a computer program. In some embodiments, the computer program can be electronically downloaded to the computer, and the downloaded computer program is stored on some tangible device.

[0019] In an exemplary embodiment, the 3D scanner is disposed on the robot, for example on the base of the robot, or alternatively on the arm of the robot. The robot can be provided inside or outside the paint booth. For example, the robot can be a floor-mounted robot disposed in the paint booth and mounted on the floor at a fixed position. Alternatively, the robot can be a mobile robot configured to move in and out of the paint booth as needed. In one example, the 3D scanner is disposed on the arm of a robot mounted on the floor in the paint booth, the robot communicating with at least one processor to control the movement of the arm and, consequently, the 3D scanner for scanning objects. In another example, the 3D scanner is disposed on the base of a robot that is a mobile robot, the robot communicating with at least one processor to control the movement of the robot and, consequently, the 3D scanner for scanning objects. Alternatively, the 3D scanner can be attached to the arm of a mobile robot, the robot communicating with at least one processor to control the movement of the arm and, consequently, the 3D scanner for scanning objects.

[0020] Alternatively, the 3D scanner is disposed on a rail gantry system. The rail gantry system can be provided inside or outside the paint booth. The 3D scanner is operably coupled to the rail gantry system, e.g., movably disposed on the rail gantry system, which communicates with at least one processor to control the movement of the rail gantry system and, consequently, the 3D scanner that scans the object. In another alternative embodiment, the 3D scanner is carried by a drone. The drone is movable inside and, optionally, outside the paint booth. The 3D scanner is operably coupled to the drone, e.g., carried by a drone, which communicates with at least one processor to control the movement (e.g., flying, landing, and / or otherwise) of the drone and, consequently, the 3D scanner that scans the object.

[0021] In an exemplary embodiment, the 3D scanner, while in communication with the at least one processor, detects (STEP 106) the object or otherwise locates the object. For example, the object may be moved into the general area to the paint booth. Alternatively, the object may be outside the paint booth, in the general area near the paint booth. The 3D scanner, whether located on a robot or rail gantry system, scans the general area including the object and communicates the scan data to the at least one processor, which uses the scan data to locate the object within the general area, including the object's position and / or orientation.

[0022] As described above, the at least one processor directs the 3D scanner to scan and collect surface data of the object, which is communicated to the at least one processor for processing to determine the surface and / or 3D shape of the object and / or identify the object. The 3D scanner and the at least one processor further cooperate to determine areas of the object to be painted (STEP 108). For example, the at least one processor is operable to execute an algorithm that directs the at least one processor to evaluate the data and determine the 3D shape of the object. The at least one processor can use the algorithm to evaluate the surface data and / or the 3D shape to identify areas or portions of the object's surface that require or otherwise require paint repair and / or refinishing.

[0023] In an exemplary embodiment, the identifier is applied (e.g., manually or otherwise) to the area of ​​the object to be painted (e.g., partially or completely surrounding the area requiring paint repair and / or refinishing). Non-limiting examples of identifiers include a non-contact sensing device, such as a radio frequency identification (RFID) tape, a colored tape, an RFID tag, an ultra-wideband (UWB) device, a color contrast border, and / or a polygonal border with corners or other tape or border masking material that can be readily identified by a 3D scanner in communication with at least one processor. In an exemplary embodiment, the object including the identifier is scanned with a 3D scanner, and the at least one processor determines the area to be painted using the location data of the identifier. For example, the at least one processor can recognize a polygonal shaped RFID tape border and determine that the area located inside the RFID tape border is the area to be painted.

[0024] Alternatively or additionally, the at least one processor may be in communication with and access a database. The database may include, for example, a plurality of different parts / objects, including a plurality of corresponding 3D shapes, areas, and / or portions of various parts / objects, e.g., unfinished or at least partially unpainted surfaces of the parts / objects, that require painting or additional painting. In an exemplary embodiment, the at least one processor may match the surface data and / or 3D shapes to a particular part / object in the database that includes the corresponding areas to be painted (e.g., match the surface data / 3D shapes to the corresponding 3D shapes of the particular part / object). Further, in an exemplary embodiment, the at least one processor may use the algorithm and / or database to determine a particular paint formula, including color and any special effects, as well as parameters (e.g., process parameters or process specifications, including speed, index, offset distance, air pressure, number of coats, flash time, drop frequency, and / or others) to be used to paint the areas of the object.

[0025] As described above, during the detection and determination of the area of ​​the object to be painted, the object can be inside or outside the paint booth. If the object is outside the paint booth, the object is moved inside the paint booth for painting. In an exemplary embodiment, since the position and / or orientation of the object may have been determined in the area outside the paint booth, the object is moved and positioned to a predetermined location known to at least one processor within the paint booth to avoid re-finding and / or re-detecting the object including its position and / or orientation so that the area of ​​the object can be accurately painted inside the paint booth. Furthermore, if the robot is a mobile robot and is located outside the paint booth during the detection and determination of the area of ​​the object to be painted, the mobile robot is moved into the paint booth before painting the object.

[0026] In an exemplary embodiment, with both the object and the robot located in the paint booth, method 100 proceeds to the step of holding an applicator offset from the area of ​​the object on the robot (e.g., at the end of the robot's arm) in communication with at least one processor (STEP 110). In an exemplary embodiment, the applicator is a spray gun, for example, in a refinish paint setting / application, or alternatively, in an industrial painting setting / application. In another exemplary embodiment, the applicator is a print head, for example, in a refinish paint setting, or alternatively, in an industrial painting setting. In another exemplary embodiment, the applicator is a rotary bell applicator, for example, in an industrial painting setting.

[0027] Referring to FIG. 2, when the applicator is a print head, the applicator may include one or more high transfer efficiency applicators for ejecting the coating composition. The coating composition 10 is ejected from one or more nozzles in a designed / controlled manner to form a fine stream that may or may not break up into droplets. The fluid stream is targeted to the substrate 12 such that the jets or droplets reach specific locations to form a continuous film or pattern on the substrate 12. The result is essentially no overspray (droplets missing the target) and near 100% transfer efficiency (essentially all of the paint goes to the target location). In an exemplary embodiment, the transfer efficiency of the coating composition deposited on the substrate 12 is 99.9% or greater. Some allowance should be made for starting and stopping the high transfer efficiency applicator 16. This type of device has been called a drop-on-demand, stream-on-demand, overspray-free, or ultra-high transfer efficiency applicator. The high transfer efficiency applicator 16 is distinguished from spray atomization techniques in which energy, such as air pressure, hydraulic pressure, or centrifugal energy, is introduced to create a partially controlled, random distribution of droplet size, trajectory, and velocity. The droplets of coating composition 10 can then be directed to the substrate 12 by some additional mechanism (electrostatic and / or shaping air). With paint sprays, there is always some overspray and loss of transfer efficiency.

[0028] In an exemplary embodiment, the high transfer efficiency applicator 16 is housed in or comprises a part of a printhead assembly 22. The printhead assembly 22 can comprise one or more high transfer efficiency applicators 16 in different embodiments. The coating composition 10 is ejected under pressure from the high transfer efficiency applicator 16 towards the substrate 12 to form a coating layer 14 on the substrate 12. The printhead assembly 22 does not contact the substrate 12 during application of the coating composition 10 and therefore remains spatially separated from the substrate 12 during application of the coating layer 14. The coating layer 14 has a coating layer thickness 24, and the coating layer thickness 24 can vary across the length and / or width of the coating layer surface 28. In an exemplary embodiment, the printhead assembly 22 is positioned or disposed at a distance of 1 to about 30 millimeters from the substrate 12 during application of the coating composition 10. The printhead assembly 22 can be controlled to move over the substrate 12 to make multiple subsequent passes to provide a coating layer 14 on the substrate 12, where both the coating layer 14 and the substrate 12 can be wider than the printhead assembly 22. In alternative embodiments, multiple printhead assemblies 22 can be utilized to apply the coating layer 14. In one embodiment, a second applicator 26 can be used to apply the fluid 18 (e.g., gas, shaping air) from the jetting 20 onto a surface 28 of the coating layer 14.

[0029] Referring to Figure 1, the applicator is in fluid communication with a paint source containing paint. The paint formulation can be, for example, a primer formulation, a sealer formulation, a basecoat formulation, a clearcoat formulation, a topcoat formulation, and / or a tint coat formulation. Non-limiting examples of various components that may be present in the paint formulation include one or more types of resins, such as acrylic resins, epoxy resins, polyurethane resins, and / or the like, various additives, accelerators, hardeners, water and / or solvent-based carriers that flash off during drying or curing of the paint formulation, colorants, effect pigment flakes, interference flakes, color pigments, and / or the like.

[0030] In an exemplary embodiment, method 100 proceeds with moving the applicator (STEP 112) relative to the area of ​​the object with a robot in communication with the at least one processor (e.g., via moving an arm of the robot) while depositing paint from the applicator (e.g., via a spray (e.g., atomized) or stream, etc.) onto the area of ​​the object. In an exemplary embodiment, the applicator is moved over the surface of the area of ​​the object along a path or pattern (e.g., a robot path, a spray path, a stream path, or the like) to provide complete coverage of the area with a desired coating thickness of paint.

[0031] In an exemplary embodiment, the applicator is a first applicator, the paint source is a first paint source, and the paint is a first coating. The method 100 includes moving the first applicator with a robot in communication with the at least one processor relative to the area of ​​the object while depositing the first coating from the first applicator onto the area of ​​the object. The method 100 optionally proceeds to allowing the first coating to flash after being deposited onto the area of ​​the object and releasing the first applicator from the robot. A second applicator is held offset from the area of ​​the object with the robot in communication with the at least one processor. The second applicator is in fluid communication with a second paint source that includes the second coating. The second applicator is moved with the robot in communication with the at least one processor relative to the area of ​​the object while depositing the second coating from the second applicator onto the area of ​​the object above the first coating.

[0032] In an exemplary embodiment, the method 100 optionally proceeds with allowing the second coating to be flashed after being deposited on the area of ​​the object, and releasing the second applicator from the robot. The third applicator is held offset from the area of ​​the object with the robot in communication with the at least one processor. The third applicator is in fluid communication with a third paint source including the third coating. The third applicator is moved relative to the area of ​​the object with the robot in communication with the at least one processor while depositing the third coating from the third applicator onto the area of ​​the object above the base coat. In an exemplary embodiment, the third coating is optionally flashed and the first, second and third coatings are cured. In an exemplary embodiment, multiple layers of the first coating, the second coating and independently the third coating can be deposited. Further, in exemplary embodiments, the first coating, the second coating, and the third coating are independently selected from the group of a primer, a sealer, a basecoat, a clearcoat, a topcoat, and / or a tintcoat.

[0033] In the foregoing detailed description of the present disclosure, at least one exemplary embodiment has been presented, but it should be understood that a vast number of variations exist. It should also be understood that the exemplary embodiment or exemplary embodiments are merely illustrative and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description provides those skilled in the art with a convenient road map for implementing the exemplary embodiments of the present disclosure. It should be understood that various changes can be made in the function and arrangement of elements described in the exemplary embodiments without departing from the scope of the present disclosure as defined in the appended claims. [Explanation of symbols]

[0034] 10 Coating composition 12 Substrate 14 Coating Layer 16 High transfer efficiency applicator 22 Printhead Assembly 24 Coating layer thickness 28 Coating layer surface

Claims

1. 1. A method for robotically painting an object, comprising: providing a scanner robot mechanism comprising a 3D scanner, a robot, and at least one processor in communication with the 3D scanner and the robot; detecting an object with the 3D scanner in communication with the at least one processor; determining, using the 3D scanner in communication with the at least one processor, an area of ​​the object to be painted; holding an applicator offset from the area of ​​the object with the robot, in communication with the at least one processor, the applicator in fluid communication with a paint source containing paint; moving the applicator relative to the area of ​​the object using the robot while depositing the paint from the applicator onto the area of ​​the object in communication with the at least one processor; A method comprising:

2. providing a paint booth; moving the object into the paint booth prior to holding and moving the applicator; Further comprising:

2. The method of claim 1, wherein holding and moving the applicator comprises holding and moving the applicator while the robot is disposed in the paint booth to deposit the paint on the area of ​​the object.

3. 3. The method of claim 2, wherein (i) the robot is a floor-standing robot located in the paint booth, or (ii) the robot is a mobile robot, the method further comprising the step of moving the mobile robot into the paint booth to deposit the paint on the area of ​​the object prior to holding and moving the applicator.

4. 3. The method of claim 2, wherein the 3D scanner is disposed in the paint booth, and the step of moving the object comprises moving the object to the paint booth prior to detecting and determining the area of ​​the object to be painted, and the step of detecting the object comprises positioning the object in the paint booth with the 3D scanner in communication with the at least one processor.

5. 3. The method of claim 2, wherein the 3D scanner is located outside the paint booth, and detecting the object to determine the area of ​​the object to be painted comprises detecting the object to determine the area of ​​the object to be painted with the 3D scanner in communication with the at least one processor while the object is located outside the paint booth, and moving the object comprises positioning the object at a predetermined position in the paint booth after detecting the object to determine the area of ​​the object to be painted.

6. The method of any one of claims 1 to 5, further comprising the step of providing a drone in communication with the at least one processor, the 3D scanner being carried by the drone.

7. The method of any one of claims 1 to 5, further comprising the step of providing a rail gantry system in communication with said at least one processor, wherein said 3D scanner is disposed on said rail gantry system.

8. 8. The method of claim 1, wherein (i) the applicator is a spray gun or a print head; (the 3D scanner is located on the robot); (iii) the 3D scanner is a contact scanner, a non-contact scanner, or a combination thereof; or (iv) any combination of (i) to (iii).

9. 8. The method according to any one of claims 1 to 7, wherein the 3D scanner is a non-contact scanner, the non-contact scanner being any of an Ultra Wideband (UWB) scanner, a camera scanner, a Time of Flight (TOF) camera, a sonic scanner, a laser scanner, and a Light Detection and Ranging Laser (LiDAR) scanner.

10. 10. The method of claim 1, wherein detecting the object comprises scanning the object with the 3D scanner to generate data, and determining the area of ​​the object to be painted comprises using the data by the at least one processor to determine a 3D shape of the object.

11. (i) the at least one processor is operable to execute an algorithm that directs the at least one processor to evaluate the data to determine the 3D shape of the object; (ii) the at least one processor is in communication with a database containing a plurality of parts having a plurality of corresponding 3D shapes, and the at least one processor searches the database to match the data to one of the plurality of parts to identify the corresponding 3D shape; (iii) the 3D scanner generates a point cloud as the data corresponding to the 3D shape; or (iv) Any combination of (i) to (iii) above; The method of claim 10.

12. 11. The method of claim 10, wherein the method further comprises applying an identifier to the area of ​​the object to be painted, wherein detecting the object comprises scanning the object including the identifier with the 3D scanner, and determining the area comprises the at least one processor determining the area to be painted using the identifier, wherein the identifier comprises a non-contact sensing device selected from radio frequency identification (RFID) tape, colored tape, an RFID tag, an ultra-wideband (UWB) device, a color contrast border, a polygonal border with corners, or combinations thereof.

13. the applicator is a first applicator, the paint source is a first paint source, and the paint is a first coating, and moving the applicator includes having the robot in communication with the at least one processor move the first applicator relative to the area of ​​the object while depositing the first coating from the first applicator onto the area of ​​the object; The method further comprising: Releasing the first applicator from the robot; holding a second applicator offset from the area of ​​the object with a robot in communication with the at least one processor, the second applicator in fluid communication with a second paint source including a second coating; moving the second applicator relative to the area of ​​the object with the robot in communication with the at least one processor while depositing the second coating from the second applicator onto the area of ​​the object overlying the first coating; The method of any one of claims 1 to 12, further comprising:

14. Releasing the second applicator from the robot; holding a third applicator offset from the area of ​​the object with the robot in communication with the at least one processor, the third applicator in fluid communication with a third paint source including a third coating; moving the third applicator relative to the area of ​​the object with a robot in communication with the at least one processor while depositing the third coating from the third applicator onto the area of ​​the object overlying the second coating; The method of claim 13 further comprising:

15. 1. A system for robotically painting an object, comprising a scanner robot mechanism, The scanner robot mechanism includes: a 3D scanner configured to scan the object; Robots and at least one processor in communication with the 3D scanner and the robot, the 3D scanner in communication with the at least one processor being cooperatively configured to detect the object and determine an area of ​​the object to be painted; an applicator configured to be in fluid communication with a paint source containing paint, the robot in communication with the at least one processor cooperatively configured to hold the applicator offset from the area of ​​the object and move the applicator relative to the area of ​​the object while depositing the paint from the applicator onto the area of ​​the object; A system comprising:

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