System and method for polishing a reflective surface

Abstract

A surface grinding system is presented. The system includes a robotic arm with an end effector at the end of the robotic arm. The end effector is configured to couple with a grinding article. The system also includes a movement mechanism for moving the robotic arm relative to a surface. Further, the system includes a robot controller that controls the robotic arm to execute a grinding trajectory on the surface. The grinding trajectory includes a state where the grinding article is in contact with the surface. The robot controller includes a trajectory acquisition unit that acquires the grinding trajectory. The grinding trajectory includes a surface appearance portion before reaching an end point. The surface appearance portion includes a decrease in the relative movement speed between the robotic arm and the grinding article, or a decrease in the effective force applied to the grinding article. Further, the controller includes a command generation unit that transmits the grinding trajectory to the movement mechanism to execute the trajectory.

Description

Background Art

[0001] Clear coat repair is one of the last processes to be automated in the original equipment manufacturing (OEM) sector of automobiles. Defect repair presents many challenges in automation. Reflective materials present unique challenges in automation.

Summary of the Invention

[0002] A surface polishing system is presented that includes a robotic arm with an end effector at an end thereof. The end effector is configured to couple with a polishing article. The system also includes a movement mechanism that moves the robotic arm relative to a surface. Further, the system includes a robot controller that controls the robotic arm to execute a polishing track on the surface. The polishing track includes a state in which the polishing article is in contact with the surface. The robot controller includes a track acquisition unit that acquires the polishing track. The polishing track includes a surface appearance portion before reaching an end point. The surface appearance portion includes a decrease in a relative movement speed between the robotic arm and the polishing article or a decrease in an effective force applied to the polishing article. Further, the controller includes a command generation unit that transmits the polishing track to the movement mechanism to execute the track.

Brief Description of the Drawings

[0003] The drawings are not necessarily drawn to scale, and the same numbers may indicate similar components in different drawings. These drawings generally, illustratively show various embodiments discussed in this document, but do not show them in a limiting sense.

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DETAILED DESCRIPTION OF THE INVENTION

[0015] Advances in recent imaging technologies and computing systems have made it possible to inspect and repair clear coat defects at production speeds. In particular, as recently demonstrated by stereo deflectometry, it is possible to acquire images and positions of paint and clear coat defects at an appropriate resolution and with spatial information (providing coordinate position information and defect classification), thereby enabling subsequent automated spot repair. As automated imaging of the work surface progresses, an improvement in the ability to automatically process the work surface is similarly desired. For example, in the case of clear coat repair, it is desirable to repair detected defects using a robotic repair system with minimal manual intervention.

[0016] However, as discussed herein, one problem in automation is the accuracy with which a robotic system executes at start and end positions where the repair trajectory is very precisely defined. Human operators rarely reproduce the same repair motion exactly, resulting in a randomness that is difficult to reproduce with robotic systems. This random motion often results in a more desirable final appearance, especially at the end of the repair.

[0017] In robotic applications, servo motors are often utilized, which improves the ability to maintain a set speed regardless of speed control, acceleration and deceleration rates, and the magnitude of the applied force. On the other hand, pneumatic tools and many battery-powered or electric tools used in these applications do not have the ability to control these parameters individually. Therefore, it is important to find a way to reproduce the aesthetic effects achieved by human operators by taking advantage of the high controllability and efficiency of robotic applications.

[0018] As used herein, the term "vehicle" is intended to encompass a wide range of moving structures to which at least one layer of paint or clear coat is applied during manufacture. While many examples herein relate to automobiles, it is expressly contemplated that the methods and systems described herein are also applicable to trucks, trains, ships (motorized or non-motorized), airplanes, helicopters, and the like. Further, while embodiments are exemplified with vehicles as being particularly useful, the systems and methods described herein are applicable to surface treatment in other industries such as painting, adhesive treatment, or material removal (e.g., sanding or polishing of wood, plastic, paint).

[0019] As used herein, the term "paint" broadly refers to each layer such as e-coat, filler, primer, paint, clear coat, etc. applied in the finishing process of a vehicle. Also, the term "paint repair" includes the operation of identifying and repairing visual defects (defective areas) existing on or within these paint layers. In some embodiments, the systems and methods described herein utilize the clear coat as the paint layer to be repaired. However, the presented systems and methods are applicable to any paint layer, such as e-coat, filler, primer, paint, clear coat, etc., with minor modifications.

[0020] As used herein, the term "defect" refers to an area that hinders the visual aesthetics of the work surface. For example, many vehicles have a glossy or metallic appearance after painting. "Defects" may include foreign matter trapped within multiple paint layers of the work surface. Also, defects include paint stains, over-application (e.g., paint rubbing or dripping), and even dents.

[0021] Figure 1 is a schematic diagram of a robotic paint repair system in which embodiments of the present invention are useful. System 100 generally includes two units, namely a vision inspection system 110 and a defect repair system 120. Both systems are controlled by motion controllers 112 and 122 respectively, which can receive commands from one or more application controllers 150. The application controller can receive inputs or provide outputs to a user interface 160. The repair unit 120 includes a force control unit 124 that can be aligned with an end effector 126. As shown in Figure 1, the end effector 126 includes two processing tools 128. However, other configurations are also explicitly envisioned.

[0022] The mainstream of current vehicle paint repair technology is a method of manually grinding / polishing defects using fine abrasives and / or a polishing system to remove them, with or without power tools, while maintaining a desired finish (e.g., maintaining the mirror finish of the clear coat). Skilled practitioners performing such repairs utilize their senses to monitor and adjust the progress of the repair while leveraging their long-term training. It is difficult to replicate such sophisticated actions with robotic solutions having limited sensing capabilities.

[0023] Furthermore, while abrasive removal is a pressure-driven process, many industrial manipulators generally operate in a position-tracking / control regime and are optimized with position accuracy in mind. As a result, they become extremely high-precision systems with a very hard error response curve (i.e., a small displacement in position causes a very large corrective force), making them unsuitable for effort control (joint torque and / or Cartesian force). To address this, a closed-loop force control approach has been used, but its practicality is limited. Recently, a more successful force control flange has been introduced, providing a flexible (not hard) displacement curve, making it suitable for sensitive force / pressure-driven processes. However, robust process strategy / control challenges still remain and are the focus of this study.

[0024] As described herein, the post - repair inspection may be performed immediately after repair, for example, using an imaging system attached to the opposing position 128 of the repair tool. In other embodiments, the post - repair inspection may be performed by a second imaging system attached to the robot unit 110, in which case the pre - repair and post - repair imaging is performed by the same imaging system or by part of a dual - mount imaging system. Also, in another embodiment, the post - repair imaging may be performed by a third robot system (not shown in FIG. 1).

[0025] Furthermore, although the systems and methods herein are discussed in the context of post - repair, it is explicitly envisioned that they are also available for pre - repair inspections to provide information about the defect repair process. For example, the inspection system 110 or other systems described herein can perform an overall inspection of the vehicle 130 to identify the location and type of defects. Thereafter, a second inspection is performed by the same or a different system to obtain a higher - resolution image of the defect and more accurate location information. This second inspection may be used to provide additional feedback to the defect repair system 100 and may include, for example, changing the polishing step from 3 seconds to 5 seconds. In other embodiments, a second or third inspection is performed after repair to confirm that the defect has been repaired and to understand the impact of the repair on the surface (e.g., removal of orange peel, occurrence of haze or scratches, etc.).

[0026] Figures 2A - 2C show defects that may occur during the clear coat repair process. Figures 2A - 2C show exemplary images of the surface taken after repair. In an automated robot - painted finish, paint defects are polished with a sanding disk. This removes the defects but creates scratches on the surface. These sanding scratches are removed by a buffing process using an abrasive. However, the buffing process may create very fine scratches that appear as haze at a specific light angle on the surface. The haze is not visible at all angles but is considered an undesirable surface appearance by customers, so it is desirable to reduce or avoid it as much as possible.

[0027] Furthermore, the "pinwheel effect" may also be seen in the context of robotic polishing. In particular, as shown in Figure 2D - 2, certain haze defects called "pinholes" or "holograms" that may be seen after the buffing process on the clear coat surface are known to be caused by fine scratches formed on the surface.

[0028] Paint defects formed during the painting process are often removed using abrasives. However, during the polishing process, the surface texture may change or "be damaged", and the appearance of the repaired area may change. The purpose of the polishing process is to remove all sanding scratches and restore a mirror - like surface, but fine scratches may occur and cause a hazy appearance on the surface.

[0029] Figures 2A - 2D show images of the surface after repair of defects that may occur during the repair process. Some defects can be addressed by changing the trajectory, such as in U.S. Provisional Patent Application No. 17 / 756,444 filed on November 24, 2020. Other defects may be addressed by additional processes after repair.

[0030] Figure 2A shows an image 200 of the surface after repair. The surface has a texture 210 called "orange peel" because it resembles the surface of an orange peel. The repair area 220 contains the repaired defect 230. Repairing a defect does not necessarily mean completely removing the defect, and may include shaving the defect to smooth the surface or correcting the defect in other ways to make it less noticeable. As shown in Figure 2A, a distinct perimeter of the repair area 220 is visible and may be visible to the human eye, which is undesirable. It is desirable to repair the defect area 220 without a distinct interruption in the orange peel texture 210.

[0031] Figure 2B shows the haze on the surface 240 after repair. As shown in Figure 2B, the haze is not uniform across the surface and is actually higher in the area 260 with the repair area than in the other area 250, often resulting in a "bull's-eye" appearance. Since the repair track used on the surface 240 ended in the area 260, a "bull's-eye" is formed there. Based on the image shown in 240, the haze value can be quantified. For example, the average haze value H of the entire repair area is estimated by the following formula: H=(1-(Li / 255))×100 Here, Li is the average light intensity value of the repair area. The haze appearance in spot repair is not visible to the human eye when H is less than about 13.

[0032] Figure 2C shows a processed image of the repair surface 270 revealing a scratch 280 that occurred on the surface during the repair process.

[0033] Defect repair generally involves polishing the surface using a first polishing article (e.g., a sanding pad) and then polishing the surface using a second polishing article (e.g., a buffing pad containing a polishing compound). The first polishing article is used to rapidly reduce the height of the defect or rapidly remove material. Usually, the coarseness of the abrasive particles in the polishing article determines the material removal rate. Generally, the higher the material removal rate, the coarser the scratches remaining later. Therefore, a second polishing medium (e.g., a buffing pad containing a polishing compound) is used to polish the surface and remove the scratches caused by the first polishing article. However, as shown in Figure 2B, while the polishing process removes scratches by polishing, it leaves many fine scratches, which may form a hazy appearance. In a robotic process, a gradient may occur in the color tone of the haze, and a dark area may occur at the end of the polishing track.

[0034] Figures 2D-1 and 2D-2 show "pinwheel" or "hologram"-like haze patterns resulting from the polishing process. Fine scratches can scatter the reflection of light and reduce the specularity of the surface, potentially causing a hazy appearance. The haze appearance may be formed in a specific pattern and has been found to be more prominent when using an automated buffing tool. In manual operation, when a person performs the buffing process, the direction of the fine scratches is approximately random. However, in an automated process, when using a simple spiral-like orbit, the scratches align along the spiral orbit program used. This phenomenon is thought to be because the buffing tool attached to the robotic arm precisely follows a predefined complete geometric orbit, making it easier for scratches to be formed in a specific direction. The "pinwheel" haze pattern can be clearly observed by rotating the surface with illumination light around the surface or rotating the panel under a fixed light.

[0035] However, other patterns may also have fine scratch patterns that match the repair geometry. For example, a repair pattern by reciprocating motion may also produce a haze pattern that matches that pattern.

[0036] FIG. 2D-1 shows a schematic view of the buffer area 242 with the pinwheel line 244, and FIG. 2D-2 shows the buffer area 246 with the pinwheel line 242. Such defects are often called "hologram" defects because the pinwheel line 242 appears to move when the viewing point changes. Under direct sunlight, general haze may be difficult to see, but "pinwheel" haze can be very prominent.

[0037] Haze is a surface appearance that is unacceptable to most customers. Therefore, it is desirable to find systems and methods for reducing the appearance of the "bull's-eye" haze shown in FIG. 2B and the "pinwheel" haze (or other patterns associated with the programmed track) shown in FIG. 2D.

[0038] Haze can be reduced by decreasing the aggressiveness of the polishing or buffing process. However, this usually requires the use of a milder polishing pad and / or abrasive. As a result, with milder polishing, it may take a significantly long time to completely remove the sanding scratches that occurred in the previous repair process. Since most vehicles have multiple defects that need to be repaired, even a slight increase in the cycle time for each defect will have a significant impact on the overall repair time for each vehicle, and the number of vehicles that can be repaired per shift will decrease. Also, as the polishing time increases, the internal temperature of the polishing pad rises, which may shorten the life of the pad. Therefore, a solution is needed that can sufficiently remove the sanding scratches, minimize the haze, and not significantly increase the cycle time or shorten the life of the polishing pad.

[0039] Figures 3A - 3B are schematic diagrams showing surface treatment operations by which the embodiments described in this specification can be implemented. Figures 3A - 3B show a simplified schematic diagram of a polishing article 310 moving along a track 316 on a flat surface 320. The state where a polishing compound 322 is applied on the surface 320 is shown. However, in many repair operations, especially in automotive repair, the surface often has curvature, and it is clearly assumed that a robotic polishing unit (not shown in Figure 3A) uses a spindle 312 to move the polishing unit 310 along the surface 320. A force 318 is applied to the polishing article 310 by a force control unit of the robotic polishing system or the like, so that the polishing article 310 is pressed against the surface 320. In some embodiments, the polishing article 310 may rotate as simple orbital rotation, random orbital rotation, vibration, or other motion patterns.

[0040] Figure 3B shows a very simple spiral track with nine waypoints on a spiral track 350. This is for illustrative purposes only, and other tracks (straight lines, orbital motion, figure - eights, rose curves, hypotrochoids, or other suitable track shapes) are clearly assumed.

[0041] In the illustrated example, the track starts contact at a point 360 where the polishing article 310 contacts the surface. As shown in Figure 370, at each waypoint 359 - 351, the polishing article 310 has a rotational speed, a moving speed (e.g., the movement from 352 to 351), and an applied force for pressing the polishing article 310 against the surface 320.

[0042] As shown in the chart 370, many parameters can change along the track 350. The term "track" as used in this specification refers to a time - dependent track from the waypoint 360 to 351. At each point of the track, the polishing article moves at a certain speed, applies a force to the surface, and operates at a speed of rotation (or orbital motion, random orbital motion, or vibration).

[0043] When the repair path reaches the end, the robotic arm is typically thought to decelerate as it approaches point 351 or to rotate in place at point 360. Such rotation in a fixed position is thought to be the cause of the problematic haze.

[0044] Figures 4A - 4C show a line scan array imaging system corresponding to a curved surface. To quantify and understand the haze, the imaging system is used to photograph the haze. Imaging of the reflective surface presents the problem of glare, and imaging of the curved surface involves problems due to the change in distance.

[0045] The system shown in Figures 4A - 4C is one system that can be used to photograph the haze, but it is also explicitly assumed that other suitable systems may be used. Also, it is explicitly assumed that the systems and methods described herein may be implemented in a robotic repair system without using a vision system or without feedback from a vision system. For example, for the repair of defects in a location visible to the customer (e.g., on the bonnet), a path that reduces the haze may be selected.

[0046] Figures 4A - 4C show a line scan array imaging system corresponding to a curved surface. For the line scan array to obtain a high - precision image and perform image post - processing and quantification, it is necessary to place the sensor mechanism at a position where the distance and angle from the reflection point are known. Also, the line scan array needs to be placed at an accurate angle with respect to the surface of the object being photographed. It is desirable that a right angle is formed between the line scan array and the light source with respect to the surface. In some embodiments, the distance sensor first scans the work surface to obtain accurate distance and curvature information, and then the line scan array is used in a second scan. In this second scan, the line scan array is adjusted to be placed at a position perpendicular to the surface at each point it inspects. In other embodiments, the distance sensor is placed in front of the line scan array. Based on the feedback from the distance sensor, the position of the line scan array with respect to the work surface is adjusted in place.

[0047] Figure 4A shows a schematic diagram of an imaging system 400 that photographs surface 402. A line scan array 410 behind lens 420 faces surface 402 and is arranged such that the right angle between line scan array 410 and light source 440 is orthogonal at point 404 on surface 402, and line scan array 410 acquires an image of surface 402.

[0048] Imaging system 400 also includes a distance sensor or a distance sensor array. In many vehicles, since there are surfaces with curvature in multiple directions, it is important to at least acquire distance information for the length that line scan array 410 passes through. As described above, in some embodiments, the distance sensor moves separately from system 400 and is shown as sensor position 430b. Also, sensor position 430b indicates the real-time position of the sensor relative to system 400 and represents the case where the sensor array moves across surface 402 as indicated by arrow 406. In some embodiments, the sensor array is mechanically connected to system 400.

[0049] In some embodiments, the sensor array is mechanically connected to system 400 and the sensor array moves along path 406 at a position fixed to system 400. By moving the entire system 400 across surface 402 with the sensor array at position 430a, the distance sensor acquires the exact topography of surface 402, and system 400 acquires an image of surface 402 in a second scan.

[0050] As shown in the transition from Figure 4A to Figure 4B, the orientation of imaging system 400 changes to maintain a right angle with respect to point 404 being photographed. Based on information from the position sensor array, a robotic arm or other movement mechanism of system 400 rotates system 400 to maintain a desired distance and orientation with respect to surface 402. A surface with one-direction curvature (zero Gaussian curvature), such as a cylindrical surface, requires one sensor array, but a surface with non-zero Gaussian curvature, such as a spherical surface, may use multiple sensor arrays.

[0051] It is desirable to manage the device settings such as the polishing minimally required to remove defects, the polishing to achieve the required surface finish, and the applied force, dwell time, and moving speed to reduce haze and scratches. The systems and methods herein provide feedback useful for improving robot control.

[0052] FIG. 4C shows an imaging system according to an embodiment herein. The imaging system 470 is controlled by a controller 480 that receives instructions from an operator using a keyboard. However, in some embodiments, the system 460 may be automatically controlled by the controller 480 and operate based on information received from, for example, a distance / position sensor or other information sources. The system 470 is an example of an imaging system that can image and quantify haze. The system 470 is shown as an example of an imaging system that can image a flat surface in a fixed location. However, as discussed herein, in some embodiments, the imaging system is designed to move along the curvature of the surface.

[0053] The line scan array 470 images the surface 466, and in some embodiments, the surface 466 is configured to move relative to the system 460. However, in other embodiments, it is explicitly contemplated that the system 460 may move while the work surface remains stationary. The light source 462 is directed at the surface 466 such that light is reflected onto the line scan array 470.

[0054] The orientation adjustment component 464 is shown as a curved rail and is used to adjust the orientation with respect to the working surface 466 of the system 460 while maintaining a desirable orientation between the light source 462 and the line scan array 470. Such a configuration is particularly useful when the surface 466 has a curvature, and it is desirable to maintain the right-angled orientation formed by the light source 462 and the line scan array 470. In this embodiment, the orientation adjustment component 464 operates independently and changes the angles of the light source 462 and the imaging device 470 with respect to the surface 466. This configuration may be preferred because the optimal arrangement for revealing and characterizing defects may vary depending on the optical properties of the surface, the angle of incidence of light, and the position of the camera.

[0055] Surprisingly, it has been found that the velocity reduction towards the final point of the orbit and the rotation at a fixed position at the final point cause local haze patterns as shown in FIGS. 2B and 2D-2. FIGS. 5A-5B show images obtained using the systems of FIGS. 4A-4C under different process conditions and using different polishing compounds.

[0056] FIGS. 5A-5B show the process parameters and the results of the polishing operations described herein. The conditions used include 3M K211 polish (0.25 g), 3M 28874 polishing pad, spiral orbit, a total polishing time of 14 seconds, and an applied force of 25 N.

[0057] In most robotic buffing processes, it begins with lowering a buffing pad onto the surface and rotating the buffing pad while moving the surface to be repaired along a specified trajectory. This operation is continued for a specified time, after which the buffing pad stops moving on the trajectory, the speed (rotation speed) of the buffing pad decreases to zero, and the tool is lifted from the surface. This operation forms a haze area concentrated within the overall haze affected area, here called the "bull's-eye" area. This bull's-eye is only visible to the human eye at a specific light angle, but can be very prominent depending on the degree of haze. Also, in addition to the overall severity of the haze, there is a phenomenon known as "hologram". In this phenomenon, fine scratches align along the trajectory pattern, making the haze pattern clearer, the haze moves in response to changes in the light angle and viewing point, and becomes more intense in certain areas. This hologram effect is particularly problematic under very bright light (e.g., sunlight), and with just a slight change in the observer's relative angle to the surface, the entire surface appears to "move" or "dance".

[0058] It has been found that by introducing a specific custom robotic buffing trajectory, both the bull's-eye and pinwheel effects can be significantly reduced. By reducing the rotation speed of the buffing pad to zero before stopping the trajectory, the pinwheel effect was significantly reduced. In another method, by lifting the buffing pad from the surface before stopping the trajectory, it was shown that the bull's-eye was significantly reduced.

[0059] Figure 5A-1 shows the haze resulting from the process conditions applied to the reflective surface, indicating that the surface (Figure 5A-2) was photographed using the system of Figure 4C and the haze was clearly visualized. Due to the speed reduction, the pinwheel effect was surprisingly reduced.

[0060] Details are described in Example 1. However, it was predicted that by changing the speed and / or the force of contact, the probability of generating fine surface scratches would increase and the haze would deteriorate. Moving a product containing minerals slowly over the surface was considered to have an adverse effect on the surface finish. This was because similar results were known for hand tools, which are also described in detail in Example 1.

[0061] In Figure 5A-1, it was confirmed that the haze was improved to some extent by reducing the rotational speed to zero. However, it should be noted that the hologram effect was significantly reduced.

[0062] As shown in Figure 5B-2, it was confirmed that the surface finish was improved by significantly reducing the force before the polishing article reached the end of the orbit.

[0063] Reducing the force and / or the relative position applied by the polishing article to the surface (e.g., moving the robotic arm to reach the final position of the orbit) shows a measurable improvement in the surface finish. By reducing the rotational speed towards the end of the orbit, the haze is reduced and the hologram effect on the surface is also reduced. Improvements are seen with any of these changes, but by combining a reduction in speed with a reduction in the applied force / relative position, surprising results were obtained. As shown in Figure 5B, when the rotational speed was reduced to zero and the applied force was significantly reduced, the haze was significantly reduced. In the example of Figure 5B-2, the applied force was reduced enough for the polishing article to be lifted off the surface. A similar effect can also be achieved by changing the relative position.

[0064] The change in the applied force can be realized in either of two ways. In some embodiments, when the robotic polishing system includes a force control unit, the applied force can be adjusted. In other embodiments, the relative position of the robotic arm with respect to the surface to be polished can be adjusted. Particularly in the polishing operation, the polishing pad is compressed against the working surface. By moving the robotic arm away from the surface, changing the relative position results in a decrease in the applied force. Any one or both of these applied force adjustments can be used in the embodiments of this specification.

[0065] Figure 6 shows a schematic diagram of a surface treatment operation according to an embodiment of the present specification. The final point 620 of the trajectory is shown in the schematic diagram 600. While sufficiently buffing / polishing the surface to remove polishing scratches, it is desirable to perform timely deceleration and / or lifting to reduce haze.

[0066] Different overall repair trajectories are suitable for different defects and are selected as discussed, for example, in U.S. Provisional Patent Application No. 17 / 756,444 filed on November 24, 2020, and PCT Publication WO 2022 / 038491 published on February 24, 2022. Once the trajectory is selected based on the type, shape, and size of the defect, the trajectory needs to be modified to account for the initial defect removal process (e.g., sanding process) and include customized deceleration. For example, an image of the defect area after sanding can be acquired, and the polishing trajectory can be modified based on the success of the sanding operation to increase or decrease the polishing time and adjust the aggressiveness of the polishing (e.g., rotational speed and applied force) to achieve the desired surface appearance.

[0067] A portion of the trajectory may be modified, particularly to reduce haze. As shown in Figure 6, the penultimate point 610 is then calculated based on the time required to rapidly decelerate the rotational speed (or vibration, orbital motion, random orbital motion speed) of the polished article. The speed may decrease significantly, for example, by 50% or more, 60% or more, 70% or more, 80% or more, 90% or more, or even completely to zero.

[0068] Furthermore, or alternatively, the trajectory is modified to reduce the applied force. This reduction can be achieved by changing the z-axis position relative to the surface of the polished article and / or by changing the applied force.

[0069] The distance 630 represents the time and / or distance required to perform surface appearance trajectory correction. This trajectory correction may include rapid deceleration, lifting / reduction of the applied force, or a combination of both.

[0070] Figure 7 shows a method of modifying a polishing repair solution according to an embodiment of the present specification. Method 700 can be performed in-situ by a robot controller based on the amount of material removed in the previous polishing step, the desired surface appearance, or other specifications. For example, defects at different positions on a vehicle may have different priorities based on visibility or the color of the vehicle. For example, a black vehicle may be less haze-resistant than a white vehicle, and a defect on the hood of a vehicle may be less haze-resistant than a defect on the roof of the vehicle.

[0071] In block 710, a polishing repair solution is generated. The repair solution is generated by selecting a trajectory 712 and a force profile 714 based on the required polishing. For example, it is selected based on the amount of material removed during a sanding process. The repair solution may be generated based on the position of the defect, the type of defect, or other parameters. Other considerations 716 may also affect the repair solution.

[0072] In block 720, the repair solution is modified based on the needs of the surface appearance. Surface appearance modification may include a reduction in speed 722 in some embodiments. In some embodiments, surface appearance modification may include a change in the z-axis position 724 relative to the surface of the polished article and / or a reduction in the applied force. In some embodiments, both the speed and the applied force / z-axis position are modified 726. Other parameter modifications 728 may also be included.

[0073] In block 730, the repair solution is further modified. The goal of method 700 is to achieve the desired surface appearance while maintaining a short cycle time. Therefore, it is possible to further reduce haze by extending the entire trajectory or adding additional trajectory steps, but it is desirable to achieve the required surface appearance while minimizing the impact on the cycle time. In some embodiments, the increase in cycle time is less than 20% or less than 10%.

[0074] Figure 8 shows a method for polishing a surface according to an embodiment of the present specification. Method 800 is used after an initial sanding process, a polishing process, or other polishing processes to provide a desired surface appearance of the work surface.

[0075] A buffing or polishing step 810 is performed. This buffing step is completed by a polishing article coupled to a robotic arm. The robotic arm moves the polishing article along a trajectory 812 and applies an appropriate force profile 814 along the trajectory 812. The trajectory may include other relevant parameters 818 such as angle, rotational / orbital speed, random orbit, or vibration.

[0076] A transition step 820 occurs between the buffing step 810 and the end 830 of the polishing operation. This operation may end by lifting from the surface as shown in Figure 8. However, it is explicitly assumed that the polishing article does not need to be completely separated from the work surface for the operation to be considered complete.

[0077] During the transition step 820, the robotic arm continues to follow a trajectory 822. This trajectory may be the same as or a modified version of the trajectory 812. For example, the speed along the work surface may increase or decrease as the end point is approached. The force applied to the polishing article, or the z-axis position 824 of the polishing article relative to the work surface, may change. The applied force may decrease by 30%, 40%, 50%, 60%, 70%, 80%, 90%, or completely separate by adjustment of the force control unit or change in the z-axis position of the polishing article relative to the work surface. The rotational speed 826 (or orbital motion / random orbit speed) of the polishing article may also decrease, and the rate of decrease may be 50%, 60%, 70%, 80%, 90%, or 100%. Other parameter values 828 may also be adjusted to achieve a desired surface appearance.

[0078] Skilled workers using hand tools can achieve a reduction in force and speed, but they cannot consistently and reproducibly achieve a reduction in force and / or speed while maintaining an efficient cycle time.

[0079] In some embodiments, the transition step 820 is completed in less than 3 seconds, less than 2 seconds, or less than 1 second.

[0080] FIG. 9 shows a robotic polishing system according to an embodiment of the present specification. The robotic polishing system 900 includes or is communicatively coupled to an imaging system 910 that captures an image of a surface. This image is analyzed by a surface analyzer 950 to select a trajectory for repairing the detected defect and is used to generate a repair solution. The imaging system 910 may include a movement mechanism 922 that moves close to the surface and other functions 924.

[0081] The image receiving unit 952 can receive an image from the image capturing device 912. The received image is analyzed by an orange peel analyzer 954 that analyzes the level of orange peel (orange peel-like pattern) around the repair site. This allows the repaired surface to be integrated with the surrounding unpolished area and determines whether the integration was successful after the operation. The defect analyzer 956 determines the type, size, and severity of the defect to be repaired before the polishing operation and is used to determine whether the defect has been sufficiently removed after the polishing operation. The haze evaluation unit 958 is used to determine whether the haze remaining after the polishing operation is within an acceptable range. The scratch evaluation unit 964 is used to evaluate scratches between each step of the polishing operation and after the completion of the polishing operation. The surface analyzer 950 may also include other functions 966.

[0082] Based on the surface condition of the work surface 990, the trajectory generation unit 930 generates a modified trajectory based on a default repair trajectory (e.g., selected based on the results of the previous polishing operation or the initial analysis of the surface 990 before repair) to achieve the desired surface appearance conditions.

[0083] The trajectory acquisition unit 932 acquires an initial trajectory. For example, it acquires from a database of trajectories (not shown) or a controller 960 that generated the initial trajectory. The cycle time acquisition unit 934 acquires the cycle time of the acquired trajectory and the cycle time limit for defect repair. For example, since some defects are expected to take a long time to repair, it may be more desirable to extend the cycle time for specific defects than to deal with haze after defect repair. Some defects may be considered too large or too complex and may be determined to be unrepairable. Similarly, when the time to address concerns regarding the surface appearance exceeds the cycle time constraint, the surface appearance repair step or the entire defect repair may be postponed. The trajectory generation unit can also acquire the surface appearance tolerance value 938. For example, more haze may be tolerated depending on the color of the surface or the position of the repair area. For example, the roof of a truck is rarely seen, so it has high haze resistance, while the bonnet of the same truck has high visibility and thus low haze resistance.

[0084] The trajectory correction unit 940 determines the trajectory distance 942 required to achieve a reduction in speed and / or applied force related to an acceptable haze appearance on the working surface 990. The trajectory distance 942 is selected to ensure sufficient distance (and trajectory time) for performing surface appearance correction while maintaining an efficient cycle time for specific defects.

[0085] Surface appearance correction may include a change in the applied force 944 (e.g., a change in the force applied by the force control unit 904). It may also include a change in the z-axis position 946 at which the polishing article 902 contacts the working surface 990. When the polishing article 902 is a compressible article, by changing the z-axis position of the contact point at the tip of the arm of the movement mechanism 906, a part of the polishing article 902 can be kept in contact with the working surface 990. Surface appearance correction also includes a decrease in the speed 948 of the polishing article 902. For example, while the polishing article 902 is moving towards the end of the orbit, by reducing the rotational, orbital, random orbital, or vibration speed, the polishing article 902 can be made to be at a lower speed or in a stationary state when the repair orbit ends. Other parameters 936 (attack angle, movement speed across the working surface 990, or other suitable parameters) may also be adjusted by the orbit correction unit 940.

[0086] In some embodiments, the working surface 990 itself may include a movement mechanism 994. The orbit may include the operations of the movement mechanism 906 and / or the movement mechanism 994. The working surface 990 may be a vehicle and may have curvature in one or more directions. In this case, the movement mechanism 906 and / or 994 move the polishing article 902 along the curvature of the working surface 990.

[0087] FIG. 10 shows the architecture of a robotic polishing system. An embodiment of a robotic polishing system 1070 that interacts with an orbit generation unit 1010 that generates an orbit for obtaining a desired surface appearance is shown in a surface treatment system architecture 1000. Although the orbit generation unit 1010 is shown separately from the robotic polishing system 1070, it is also explicitly assumed that the controller of the robotic polishing system 1070 may be integrated.

[0088] For example, the surface treatment system 1000 provides computing, software, data access, and storage services, and enables end users to not need knowledge about the physical location and configuration of the system providing these services. In some embodiments, a remote server may provide services using an appropriate protocol via a wide area network (e.g., the Internet). For example, a remote server may provide applications via a wide area network, and these are accessible through a web browser or other computer components.

[0089] The software or components shown in FIGS. 1 - 9, and the corresponding data, may be stored on a server at a remote location. The computing resources of the remote server environment may be integrated or distributed in a remote data center. The remote server infrastructure can provide services through a shared data center and is recognized by users as a single access point. Therefore, the components and functions described herein may be provided from a server at a remote location using a remote server architecture. Alternatively, they may be directly installed on a conventional server or client device, or provided in other ways.

[0090] FIG. 10 specifically shows that the trajectory generation unit 1010 can be arranged at the remote server location 1002. Therefore, the computing device 1020 accesses these systems via the remote server location 1002. The operator 1050 can also access the user interface 1022 using the computing device 1020.

[0091] FIG. 10 shows that some elements of the systems described herein may be located at remote server location 1002 while other elements may not be. For example, storage 1030, 1040, or 1060, or robotic system 1070 may be located at a location separate from location 1002 and may be accessed via a remote server at location 1002. Regardless of where they are located, they may be directly accessed by computing device 1020, hosted as a service accessible via a network (wide area network or local area network), or accessed by a connection service existing at a remote location. Further, data may be stored almost anywhere and may be accessed intermittently as needed or transferred to interested parties. For example, a physical carrier may be used instead of or in addition to an electromagnetic wave carrier.

[0092] Furthermore, elements of the systems described herein, or portions thereof, may be located on a wide variety of devices. These devices include servers, desktop computers, notebook computers, embedded computers, industrial controllers, tablet computers, or other mobile devices (e.g., handheld computers, cell phones, smart phones, multimedia players, personal digital assistants, etc.).

[0093] FIGS. 11-12 show examples of computing devices that may be used in the embodiments shown in the figures.

[0094] FIG. 11 is a simplified block diagram showing an example of a handheld or mobile computing device that can be used as a user or client handheld device 1116 (e.g., computing device 1020 of FIG. 10) on which a current system (or a portion thereof) is deployed. For example, the mobile device may be deployed in the operator compartment of computing device 920 and may be used for data generation, processing, or display.

[0095] FIG. 11 provides a general block diagram of a client device 1116 that can execute some of the components shown and described herein. The client device 1116 can interact with these and / or interact with others while executing some of them. The device 1116 is provided with a communication link 1113 for communicating with other computing devices and, in some embodiments, provides a channel for automatic reception of information by scanning. Examples of the communication link 1113 include wireless services that provide cellular access to a network and protocols that provide local wireless connection to a network.

[0096] In other examples, the application is received via a removable Secure Digital (SD) card that is connected to the interface 1115. The interface 1115 and the communication link 1113 communicate with a processor 1117 (which may embody the processor itself) and are also connected via a bus 1119 to a memory 1121, input / output (I / O) components 1023, as well as a clock 1125 and a position system 1127.

[0097] The I / O components 1123 are provided in some embodiments to facilitate input and output operations. The device 1116 includes input components such as buttons, touch sensors, light sensors, microphones, touchscreens, proximity sensors, accelerometers, direction sensors, etc., and output components such as display devices, speakers, or printer ports. Other I / O components 1123 are also available.

[0098] The clock 1125 includes a real-time clock component that outputs time and date. This also provides a timing function for the processor 1117.

[0099] The location system 1127 includes components that output the current geographical location of the device 1116. This may include, for example, a Global Positioning System (GPS) receiver, a LORAN system, an inertial navigation system, a cellular triangulation system, or other location systems. It may also include mapping software or navigation software that generates destination maps, routes, and other geographical functions.

[0100] The memory 1121 stores an operating system 1129, network settings 1131, applications 1133, application settings 1135, a data store 1137, a communication driver 1139, and communication settings 1141. The memory 1121 includes all types of computer-readable physical memory devices, both volatile and non-volatile. It also includes the computer storage media described below. The memory 1121 stores computer-readable instructions that, when executed by the processor 1117, cause the computer-implemented steps or functions to be executed in accordance with the instructions. The processor 1117 may be activated by other components and may facilitate their functions.

[0101] FIG. 12 shows a block diagram of a computing environment that can be used in the embodiment shown in the figure.

[0102] FIG. 12 illustrates an example of a deployable computing environment for elements or portions of the systems and methods described herein. Referring to FIG. 12, by way of example for implementing some embodiments, a general purpose computing device (in the form of computer 1210) is included. The components of computer 1210 include, but are not limited to, a processing unit 1220 (which may include a processor), a system memory 1230, and a system bus 1221. System bus 1221 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using various bus architectures. Memories and programs related to the systems and methods described herein may be deployed to corresponding portions of FIG. 12.

[0103] Computer 1210 typically includes a variety of computer readable media. Computer readable media is any available media accessible by computer 1210 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, computer storage media and communication media are included. Computer storage media does not include modulated data signals or carrier waves. This includes volatile / nonvolatile and removable / non-removable media implemented for the storage of information such as computer readable instructions, data structures, program modules, and other data. By way of example, RAM, ROM, EEPROM, flash memory, CD-ROM, DVD, magnetic cassettes, magnetic tape, magnetic disk storage, or other magnetic storage devices, or any other media accessible by computer 1210 are included. Communication media embodies computer readable instructions, data structures, program modules, or other data in a transport mechanism and includes any media for delivering information.

[0104] System memory 1230 includes computer storage media composed of volatile and / or non-volatile memory, including, for example, read-only memory (ROM) 1231 and random access memory (RAM) 1232. The basic input / output system 1233 (BIOS) is typically stored in ROM 1231 and includes basic routines for transferring information between components within computer 1210 during startup. RAM 1232 typically contains data and / or program modules currently being operated on that the processing unit 1220 can access immediately. As an example, FIG. 12 shows operating system 1234, application program 1235, other program modules 1236, and program data 1237.

[0105] Computer 1210 may also include other removable / non-removable and volatile / non-volatile computer storage media. As an example, FIG. 12 shows hard disk drive 1241 for reading and writing non-removable, non-volatile magnetic media, non-volatile magnetic disk 1252, optical disk drive 1255, and non-volatile optical disk 1256.

[0106] Alternatively, or in addition, the functions described herein may be at least partially performed by one or more hardware logic components. For example, hardware logic components such as field-programmable gate arrays (FPGA), application-specific integrated circuits (ASIC), application-specific standard products (ASSP), system-on-chip (SoC), complex programmable logic devices (CPLD), etc. may be used.

[0107] The hard disk drive 1241 shown in FIG. 12 and related computer storage media provide storage of computer-readable instructions, data structures, program modules, and other data for the computer 1210. In FIG. 12, for example, the hard disk drive 1241 is shown storing an operating system 1244, application programs 1245, other program modules 1246, and program data 1247. These components may or may not be the same as the operating system 1234, application programs 1235, other program modules 1236, and program data 1237.

[0108] The user can input commands and information into the computer 1210 through input devices such as a keyboard 1262, a microphone 1263, and a pointing device 1261 (such as a mouse, trackball, touchpad, etc.). Other input devices (not shown) may include a joystick, game pad, satellite receiver, scanner, etc. These and other input devices are typically connected to the processing unit 1220 via a user interface 1260 connected to the system bus, but may also be connected by other interfaces and bus structures. A visual display 1291 or other type of display device is also connected to the system bus 1221 via a video interface 1290. In addition to a monitor, the computer may also include peripheral output devices such as speakers 1297 and a printer 1296, which may be connected via an output peripheral interface 1295.

[0109] The computer 1210 operates in a network environment with one or more remote computers, such as a remote computer 1280, using logical connections such as a local area network (LAN) or a wide area network (WAN).

[0110] When used in a LAN network environment, computer 1210 is connected to LAN 1271 via network interface or adapter 1270. When used in a WAN network environment, computer 1210 typically includes a modem 1272 or other communication means to establish communication via WAN 1273 (e.g., the Internet). In a network environment, program modules may be stored in a remote memory storage device. FIG. 12 shows, for example, that remote application program 1285 exists on remote computer 1280.

[0111] A method for repairing surface defects is presented, which includes the steps of photographing the surface using an imaging system to identify the defects. The method also includes the step of selecting a first polishing track for a first polishing operation based on an instruction from the imaging system. The method further includes the step of performing a first polishing operation by bringing a first polishing article into contact with the surface. This first polishing article is pressed against the surface in the defective area by a robot repair system. The method also includes the step of selecting a second track for a second polishing operation. The second polishing operation includes the step of bringing a second polishing article into contact with the surface in the polished surface area. The second track includes any of the following: rotating the polishing article, reducing the track or random track speed by 90% or more before reaching the track end point, reducing the applied force by 90% or more before reaching the track end point, or separating the polishing article from the surface. The method also includes the step of operating a robot repair unit to execute the second track.

[0112] This method may be implemented to include obtaining a default polishing trajectory and generating a surface appearance modification of the default polishing trajectory when selecting a second trajectory. The generated surface appearance is generated based on the surface metrics obtained by the second imaging system. This method further includes calculating the path length required to perform the surface appearance modification such that the surface modification is performed before the trajectory reaches the end point. Also included is the step of generating a second trajectory by modifying the polishing trajectory to include the surface appearance modification.

[0113] This method may be implemented such that the surface appearance modification is selected from the following group: a decrease in the rotational speed of the second polishing article while in contact with the surface, a decrease in the orbital speed of the second polishing article while in contact with the surface, a decrease in the random orbital speed of the second polishing article while in contact with the surface, a decrease in the vibration rate of the second polishing article while in contact with the surface, a decrease in the applied force to the second polishing article while in contact with the surface, and the z-axis position of the end of the arm of the robotic repair system relative to the surface.

[0114] This method may be implemented such that the rotational speed is decreased to zero, the orbital speed is decreased to zero, the random orbital speed is decreased to zero, or the vibration rate is decreased to zero before the end point.

[0115] This method may be implemented such that the applied force and / or the z-axis position is decreased and the polishing article is separated from the surface before the end point.

[0116] This method may be implemented such that the second imaging system is the first imaging system.

[0117] This method may be implemented such that the first imaging system is disposed on the robotic arm of the robotic repair system.

[0118] This method may be implemented such that the first polishing article is a sanding disk and the second polishing article is a polishing pad.

[0119] A method for modifying the appearance of a reflective surface is presented, which includes the steps of bringing an abrasive article into contact with the reflective surface and moving the abrasive article along the reflective surface. The movement includes moving the abrasive article from a starting point to an ending point by a robot arm with a moving speed and an applied force. Before reaching the ending point, the moving speed for the robot arm is reduced by 50% or more.

[0120] This method may be implemented such that the moving speed is a rotational speed, an orbital speed, a random orbital speed, or a vibration speed.

[0121] This method may be implemented such that the moving speed is reduced by 90% or more.

[0122] This method may be implemented such that the moving speed is reduced by 95% or more.

[0123] This method may be implemented such that the moving speed is reduced by 99% or more.

[0124] This method may be implemented such that before reaching the ending point, the effective force applied to the abrasive article by the robot arm is reduced by 50% or more.

[0125] This method may be implemented such that the effective force is an applied force generated by a force control unit.

[0126] This method may be implemented such that the effective force is generated by a change in the position of the robot arm with respect to the reflective surface.

[0127] This method may be implemented such that the effective force is reduced by 90% or more.

[0128] This method may be implemented such that the value of the effective force is reduced to a negative value.

[0129] A method for modifying the appearance of a reflective surface is presented, which includes the step of bringing an abrasive article into contact with the reflective surface. This method further includes the step of moving the abrasive article along the reflective surface. The movement includes the robot arm moving the abrasive article from a starting point to an ending point with a moving speed and an applied force. Before reaching the ending point, the effective force applied to the abrasive article by the robot arm is reduced by 50% or more.

[0130] This method may be implemented such that the effective force is the applied force generated by a force control unit.

[0131] This method may be implemented such that the effective force is generated by a change in the position of the robot arm relative to the reflective surface.

[0132] This method may be implemented such that the effective force is reduced by 90% or more.

[0133] This method may be implemented such that the value of the effective force is reduced to a negative value.

[0134] This method may be implemented such that the effective force is reduced to less than 5 Newtons.

[0135] This method may be implemented such that before reaching the ending point, the relative speed of the abrasive article with respect to the robot arm is reduced by 50% or more.

[0136] This method may be implemented such that the moving speed is a rotational speed, an orbital speed, a random orbital speed, or a vibration speed.

[0137] This method may be implemented such that the moving speed is reduced by 90% or more.

[0138] This method may be implemented such that the moving speed is reduced by 95% or more.

[0139] This method may be implemented such that the moving speed is reduced by 99% or more.

[0140] A surface treatment system is presented, which includes a robotic arm with an end effector disposed at the end of the robotic arm. The end effector is configured to connect a polishing article. The system also includes a moving mechanism for moving the robotic arm relative to the surface. The system further includes a robot controller for causing the robotic arm to execute a polishing trajectory on the surface. The polishing trajectory includes a state in which the polishing article is in contact with the surface. The robot controller includes a trajectory acquisition unit for acquiring the polishing trajectory. The polishing trajectory includes a surface appearance portion before the end point, and the surface appearance portion includes a decrease in the relative movement speed between the robotic arm and the polishing article, or a decrease in the effective applied force on the polishing article. The robot controller also includes a command generation unit for communicating the trajectory to the moving mechanism to cause the execution of the trajectory.

[0141] The system may be implemented such that a surface appearance trajectory is generated by a trajectory generation unit including a default trajectory acquirer for acquiring a default trajectory and a surface appearance tolerance value acquirer for acquiring a surface appearance tolerance value, and the surface appearance tolerance value includes an allowable haze threshold value. The trajectory generation unit also includes a trajectory correction unit for applying a trajectory correction to the default trajectory based on the surface appearance tolerance value. The corrected default trajectory is the polishing trajectory.

[0142] The system may be implemented such that the polishing article is a compressible polishing article.

[0143] The system may be implemented such that the trajectory correction is a change in the z-axis position of the end of the robotic arm relative to the surface.

[0144] The system may be implemented to further include a force control unit. The trajectory correction is a decrease in the applied force.

[0145] The system may be implemented such that the end effector is configured to rotate the polishing article, and the trajectory correction is a decrease in the rotation speed of the polishing article while the polishing article is in contact with the surface.

[0146] This system may be configured such that the end effector orbits the polishing article, and the orbit correction may be implemented as a decrease in the orbital speed of the polishing article while the polishing article is in contact with the surface.

[0147] This system may be configured such that the end effector moves the polishing article in a random orbit, and the orbit correction may be implemented as a decrease in the random orbital speed of the polishing article while the polishing article is in contact with the surface.

[0148] This system may be configured such that the end effector vibrates the polishing article, and the orbit correction may be implemented as a decrease in the vibration frequency of the polishing article while the polishing article is in contact with the surface.

[0149] This system may be configured such that the end effector translates the polishing article along the surface, and the orbit correction may be implemented as a decrease in the translation speed.

[0150] This system may be implemented such that the controller further includes a cycle time acquisition unit that acquires a predetermined cycle time of a predetermined orbit. The corrected orbit is within the range of the cycle time tolerance value of the predetermined orbit.

[0151] This system may be implemented such that the cycle time tolerance value includes the corrected cycle time being within the range of 100% to 200% of the predetermined cycle time.

[0152] This system may be implemented such that the predetermined orbit is acquired based on a defect identified on the surface.

[0153] This system may be implemented such that the predetermined orbit is acquired based on a surface analysis of the surface.

[0154] This system may be implemented such that the polishing path is a second polishing path. This system further includes a surface imaging system that captures an image of the surface after the first polishing operation is completed on the first polishing path, and a surface analysis unit that generates a surface index based on the surface imaging. The path correction is performed based on the surface index.

[0155] This system may be implemented such that the surface index includes a surface haze index.

[0156] This system may be implemented such that the surface index includes a surface scratch severity index.

[0157] This system may be implemented to include a display configured to display the path.

[0158] This system may be implemented such that the surface has a curvature. The path includes adjusting the relative position of the end of the robotic arm with respect to the surface of the polishing article to follow the curvature.

[0159] A method for generating a path of a polishing operation is presented. This method includes selecting a default path from a path data store by a path acquisition unit. The default path includes a time-based movement path of the polishing article on the surface to be polished. This method further includes obtaining a surface appearance tolerance value of the surface. It also includes calculating a surface appearance correction of the default path based on the surface appearance tolerance value. This method further includes generating a path by modifying the time-based movement path to reflect the surface appearance correction. The surface appearance correction includes changing the parameters of the default path along the time-based movement path. This method further includes generating a command to instruct the robotic polishing unit to execute the path.

[0160] This method may be implemented to include calculating the time required to achieve further surface appearance correction when generating a trajectory and modifying the trajectory so that the surface appearance correction is completed within that time.

[0161] This method may be implemented to include replacing a portion of the trajectory with a travel path based on a time period and a modified time.

[0162] This method may be implemented such that the portion to be replaced is located at the end of the trajectory.

[0163] This method may be implemented to include adding a travel path based on a time period and a modified time to the trajectory.

[0164] This method may be implemented such that the default trajectory is based on a surface analysis after a previous polishing operation.

[0165] This method may be implemented such that the default trajectory is based on surface defects identified on the surface.

[0166] This method may be implemented to include selecting a default applied force profile for the default trajectory and generating a force control command for the force control unit for command generation when selecting the default trajectory.

[0167] This method may be implemented to include a modified applied force profile for surface correction.

[0168] This method may be implemented such that the modified applied force profile reduces the applied force by 90% before the end of the trajectory.

[0169] This method may be implemented such that the applied force profile becomes negative by the end of the trajectory.

[0170] This method may be implemented such that the default imparted force profile has a maximum imparted force and the modified imparted force profile reduces the imparted force to less than 10% of the maximum imparted force at the end of the trajectory.

[0171] This method may be implemented such that the imparted force becomes negative before the end of the trajectory.

[0172] This method may be implemented such that the reduction in the translational speed of the polishing article along the surface is included in the surface modification.

[0173] This method may include an end effector to which the polishing article is connected by a robotic repair unit, the end effector being configured to move the polishing article relative to the robotic repair unit during the polishing operation, and the surface appearance modification being implemented such that it is a reduction in the relative movement speed.

[0174] This method may be implemented such that the reduction is a stepwise decrease in speed within a time period that ends at the end of the trajectory.

[0175] This method may be implemented such that the time period is part of the time period of the trajectory.

[0176] This method may be implemented such that the end effector rotates the polishing article.

[0177] This method may be implemented such that the end effector moves the polishing article in an orbital pattern.

[0178] This method may be implemented such that the end effector moves the polishing article in a random orbital pattern.

[0179] This method may be implemented such that the end effector vibrates the polishing article.

[0180] This method may be implemented such that the translational speed on the surface of the polished article does not change from a predetermined orbit to an orbit during a time period.

[0181] A method of performing a polishing operation is presented, which includes obtaining an initial orbit of the polishing operation on the surface using an orbit acquisition unit. This initial orbit is part of a series of orbits generated for the surface. The initial orbit includes a movement path based on the time during which the polished article moves along the surface. This method further includes generating a surface appearance correction of the initial orbit based on surface appearance parameters. Also included is a step of correcting the initial orbit using an orbit correction unit to include the surface appearance correction. The initial orbit includes a first part and a subsequent second part, and the surface appearance correction corrects the second part. This method further includes a step of executing the corrected orbit using a robot repair unit. The robot repair unit moves the polished article along the corrected orbit.

[0182] This method may be implemented such that the surface appearance correction is a decrease in the applied force applied by the force control unit of the robot repair unit.

[0183] This method may be implemented such that the surface appearance correction is a decrease in the speed of the polished article relative to the robot repair unit.

[0184] This method may be implemented such that the translational speed with respect to the working surface of the polished article does not change.

[0185] This method may be implemented such that the relative movement of the polished article with respect to the robot repair unit is a rotational movement, an orbital movement, a random orbital movement, or a linear movement.

[0186] This method may be implemented such that the surface appearance correction is a change in the relative position of the end of the arm of the robot repair unit with respect to the surface.

[0187] This method may be implemented such that surface appearance parameters are generated based on surface analysis after a previous polishing operation.

[0188] This method may be implemented such that surface appearance parameters are generated based on defects detected on the surface.

[0189] This method may be implemented such that the surface appearance parameter is an acceptable haze threshold.

[0190] This method may be implemented such that the first part of the trajectory is not changed.

[0191] This method may be modified such that the second part gradually changes the polishing parameters.

[0192] This method may be modified such that the second part gradually changes the polishing parameters.

[0193] This method may be implemented such that the surface has a curvature and the initial trajectory is obtained based on that curvature.

[0194] (Example 1: Pneumatic Sanding System) Pneumatic Random Orbital Sanders (ROS) are simple air-driven tools used in many applications, but their main use, regardless of the application, is to remove material and provide an acceptable surface finish. This application may include a simple single-step process or a complex staged polishing process that uses a coarse grade abrasive in the first stage and then a finer abrasive to achieve the desired finish.

[0195] The function of the pneumatic ROS assumes that clean and dry compressed air of appropriate pressure and quantity is supplied, and that regular preventive maintenance (e.g., lubrication) is performed. To achieve the appropriate rotational speed (rpm), it is necessary to supply 90 psi of compressed air to the 3M ROS through a 3 / 8-inch inner diameter (ID) air line. It is important that the pressure of the tool is measured with the throttle actuated and the polishing system not in contact with the substrate being polished. Note that the length of the air line should be less than 25 feet to prevent pressure drop.

[0196] The pressure and quantity of compressed air directly affect the rotational speed (rpm) that a pneumatic sander can generate. Therefore, if the appropriate rotational speed is not achieved, it can be inferred that it will also affect the resulting surface finish. Surface finish measures the overall fine surface irregularities that exist after the substrate has been polished. The parameters of surface finish are diverse, but two important parameters particularly relevant to painting applications are Ra and Rz. The definitions of these parameters can be found on various websites on the Internet (e.g., https: / / www.taylor-hobson.com / resource-center / blog / 2020 / october / what-is-surface-finish-and-types-of-surface-finish-parameters). Surface finish is also affected by other factors such as the operator, the type of disk pad selected, and the structure of the item being polished. However, if factors other than air pressure are kept constant, tests can be conducted to show surface changes related to air pressure.

[0197] When setting a dynamic air pressure of 90 psi as the target, research has suggested that as the air pressure decreases (i.e., the rotational speed decreases), the surface finish generally tends to become rougher. When the speed of the polishing system decreases, the time for the polished article to interact with the substrate becomes longer, so there is a possibility of generating deeper and more aggressive scratch patterns. Such aggressive scratches tend to appear as secondary defects from the polishing process when coated. General terms for these secondary defects include "wild scratches", "penetration of polishing scratches", "color unevenness", etc. For example, in a certain study, the substrate was polished with a P120 abrasive and the dynamic air pressure was set to 90 psi. Then, the surface finish was measured. While using the same polishing system, the air pressure was decreased to 70 psi, and another area of the same substrate was polished using a new P120 abrasive of the same lot. The following results were obtained in the subsequent measurement of the surface finish: Ra: 11.4% rougher finish at 70 psi Rz: 22.2% rougher finish at 70 psi Rmax: 17.3% rougher finish at 70 psi In this case, the change in the rotational speed of the tool was measured to be approximately 1000 rpm. Although the importance of the change in the surface finish was not specified, the importance of this test was to emphasize the impact of the proper functioning of an air-driven random orbital sander on the customer's work.

[0198] (Example 2: Control Spiral (Comparative Example)) An industrial robot arm was equipped at its end with an active compliant tool (6530, 3M, St. Paul, Minnesota, USA) and a servo random orbit buffer motor (77540, 3M, St. Paul, Minnesota, USA), both manufactured by 3M. The buffer motor was directly attached to the active compliant tool. A backup pad (20350, 3M, St. Paul, Minnesota, USA) was attached to the end of the servo motor, and a polishing pad (28874, 3M, St. Paul, Minnesota, USA) was attached to the end of the backup pad. A black painted panel (57080, ACT Test Panels LLC, Hillsdale, Michigan, USA) was placed on the table at a distance of approximately 125 mm from the polishing pad.

[0199] Approximately 0.3 g of a polishing compound (K211 polishing compound, 3M, St. Paul, Minnesota, USA) was placed on the painted panel directly beneath the polishing pad. A planned path was sent from the computer to the robot. The polishing pad was pressed against the panel with a downward force of 25 N. The servo motor increased its rotational speed to 8500 rpm and simultaneously initiated a spiral motion on the X-Y plane of the painted panel. The spiral started at a radius of 5 mm, spiraled outwards to a radius of 20 mm, and performed a total spiral time of 14 seconds at a traverse speed of 0.05 m / s. After the traverse speed reached zero, the rotational speed of the servo motor decreased to zero. Subsequently, the robot lifted the polishing pad from the surface of the painted panel.

[0200] The residual polishing compound on the surface of the painted panel was wiped off using a wiping cloth (3M detailing cloth 39016, 3M, St. Paul, Minnesota, USA). The resulting polished surface was analyzed using the system described and explained in U.S. Provisional Patent Application No. 63 / 363056, filed on April 15, 2022.

[0201] The average haze value H for the entire repair area can be estimated using the following equation: H = (1 - (Li / 255)) × 100

[0202] Here, Li represents the average light intensity value of the repair area. The haze value is shown in Fig. 5A-1 "Control".

[0203] (Example 2A: Decelerating to 0 rpm) An active compliant tool (6530, 3M, St. Paul, Minnesota, USA) and a servo random orbit buffer motor (77540, 3M, St. Paul, Minnesota, USA) made by 3M were mounted on the end of an industrial robot arm. The buffer motor was directly attached to the active compliant tool. A backup pad (20350, 3M, St. Paul, Minnesota, USA) was attached to the end of the servo motor, and a polishing pad (28874, 3M, St. Paul, Minnesota, USA) was attached to the end of the backup pad. A black painted panel (57080, ACT Test Panels LLC, Hillsdale, Michigan, USA) was placed on the table and positioned at a distance of approximately 125 mm from the polishing pad.

[0204] Approximately 0.3 g of polishing compound (K211 polishing compound, 3M, St. Paul, Minnesota, USA) was placed on the painted panel directly below the polishing pad. The planned path was sent from the computer to the robot. The polishing pad was pressed against the panel with a downward force of 25 N. The servo motor increased the rotational speed to 8500 rpm and simultaneously started a spiral motion on the X-Y plane of the painted panel. The spiral started at a radius of 5 mm and spiraled outward to a radius of 20 mm, with a traverse speed of 0.05 m / s and a total spiral time of 14 seconds. Before the traverse speed reached zero, the rotational speed of the servo motor decreased to zero. Then, the robot lifted the polishing pad from the surface of the painted panel.

[0205] The residual polishing compound on the painted panel surface was wiped off using a wiping cloth (3M Detailing Cloth 39016, 3M Company, St. Paul, Minnesota, USA). The resulting polished surface was analyzed using the system described and explained in U.S. Provisional Patent Application No. 63 / 363056, filed on April 15, 2022. The haze value was calculated using the above formula and is shown in Figure 5A-1, "0 rpm Step".

[0206] (Example 2B: Lift-off) A 3M Active Compliance Tool (6530, 3M Company, St. Paul, Minnesota, USA) and a 3M Servo Random Orbital Buffer Motor (77540, 3M Company, St. Paul, Minnesota, USA) were attached to the end of an industrial robot arm. The buffer motor was directly attached to the active compliance tool. A backup pad (20350, 3M Company, St. Paul, Minnesota, USA) was attached to the end of the servo motor, and a polishing pad (28874, 3M Company, St. Paul, Minnesota, USA) was attached to the end of the backup pad. A black painted panel (57080, ACT Test Panels LLC, Hillsdale, Michigan, USA) was placed on the table and positioned at a distance of approximately 125 mm from the polishing pad.

[0207] Approximately 0.3 g of polishing compound (K211 Polishing Compound, 3M Company, St. Paul, Minnesota, USA) was placed on the painted panel directly beneath the polishing pad. A planned path was sent from the computer to the robot. The polishing pad was pressed against the panel with a downward force of 25 N. The servo motor increased the rotational speed to 8500 rpm and simultaneously started a spiral motion on the X-Y plane of the painted panel. The spiral started at a radius of 5 mm and spiraled outward to a radius of 20 mm, progressing at a traverse speed of 0.05 m / s. The spiral continued for 12.5 seconds, after which the robot lifted the polishing pad from the surface of the painted panel. The spiral continued for an additional 1.5 seconds above the surface of the painted panel, after which the rotational speed of the servo motor decreased to zero.

[0208] The residual polishing compound on the painted panel surface was wiped off using a wiping cloth (3M Detailing Cloth 39016, 3M Company, St. Paul, Minnesota, USA). The resulting polished surface was analyzed using the system described and explained in U.S. Provisional Patent Application No. 63 / 363056, filed on April 15, 2022. The haze value was calculated using the above formula and is shown in Figure 5A-1 "Lift-off".

[0209] (Example 2C: Lift-off by K211 and deceleration to 0 RPM) A 3M active compliant tool (6530, 3M Company, St. Paul, Minnesota, USA) and a 3M servo random orbit buffer motor (77540, 3M Company, St. Paul, Minnesota, USA) were attached to the end of an industrial robot arm. The buffer motor was directly attached to the active compliant tool. A backup pad (20350, 3M Company, St. Paul, Minnesota, USA) was attached to the end of the servo motor, and a polishing pad (28874, 3M Company, St. Paul, Minnesota, USA) was attached to the end of the backup pad. A black painted panel (57080, ACT Test Panels LLC, Hillsdale, Michigan, USA) was placed on the table and positioned at a distance of approximately 125 mm from the polishing pad.

[0210] Approximately 0.3 g of a polishing compound (K211 polishing compound, 3M Company, St. Paul, Minnesota, USA) was placed on the painted panel beneath the polishing pad. The planned path was sent from the computer to the robot. The polishing pad was pressed against the panel with a downward force of 25 N. The servo motor increased the rotational speed to 8500 rpm and simultaneously initiated a spiral motion on the X-Y plane of the painted panel. The spiral started at a radius of 5 mm, traced outwards to a radius of 20 mm, and advanced at a traverse speed of 0.05 m / s. After 12.2 seconds, the rotational speed of the servo motor was set to zero and decelerated to approximately 4250 rpm. Subsequently, the robot lifted the polishing pad from the surface of the painted panel at 12.5 seconds. The spiral motion was continued for an additional 1.5 seconds above the surface of the painted panel.

[0211] The residual polishing compound on the surface of the painted panel was wiped off using a wiping cloth (3M Detailing Cloth 39016, 3M Company, St. Paul, Minnesota, USA). The resulting polished surface was analyzed using the system described and explained in U.S. Provisional Patent Application No. 63 / 363056, filed on April 15, 2022. The haze value was calculated using the above formula and is shown in the "K211" column of Figure 5B-1.

[0212] (Example 2D: Combination of lift-off and deceleration to 0 rpm with 315 polish) An industrial robot arm was equipped with an active compliant tool (6530, 3M, St. Paul, Minnesota, USA) and a servo random orbit buffer motor (77540, 3M, St. Paul, Minnesota, USA) made by 3M at the end of the arm. The buffer motor was directly attached to the active compliant tool. A backup pad (20350, 3M, St. Paul, Minnesota, USA) was attached to the end of the servo motor, and a polishing pad (28874, 3M, St. Paul, Minnesota, USA) was attached to the end of the backup pad. A black painted panel (57080, ACT Test Panels LLC, Hillsdale, Michigan, USA) was placed on the table and positioned at a distance of about 125 mm from the polishing pad.

[0213] Approximately 0.3 g of polishing compound (315 polishing compound, 3M, St. Paul, Minnesota, USA) was placed on the painted panel directly under the polishing pad. The planned path was sent from the computer to the robot. The polishing pad was pressed against the panel with a downward force of 25 N. The servo motor increased its rotational speed to 8500 rpm and simultaneously started a spiral motion on the X-Y plane of the painted panel. The spiral started at a radius of 5 mm and spiraled outward to a radius of 20 mm, progressing at a transverse speed of 0.05 m / s. After 12.2 seconds, the rotational speed of the servo motor was set to zero and the speed was decelerated to about 4250 rpm. Then, at 12.5 seconds, the robot lifted the polishing pad from the surface of the painted panel. The spiral motion continued for an additional 1.5 seconds above the surface of the painted panel.

[0214] The residual polishing compound on the surface of the painted panel was wiped off using a wiping cloth (3M detailing cloth 39016, 3M, St. Paul, Minnesota, USA). The resulting polished surface was analyzed using the system described and explained in U.S. Provisional Patent Application No. 63 / 363056 filed on April 15, 2022. The haze value was calculated using the above formula and is shown in the "315" column of Figure 5B-1.

Claims

Claim 1 A method for repairing surface defects, comprising: imaging the surface to identify the defect using an imaging system; selecting a first polishing path for a first polishing operation based on an instruction from the imaging system; performing the first polishing operation by contacting the surface with a first polishing article, wherein the first polishing article is pressed against the surface in the region of the defect by a robot repair system; selecting a second path for a second polishing operation, wherein the second polishing operation includes contacting the surface with a second polishing article in the region of the polished surface, and the second path includes: reducing at least 90% of the rotational speed, path speed, or random path speed of the polishing article before reaching the end of the path; reducing at least 90% of the force applied before reaching the end of the path, or separating the polishing article from the surface before reaching the end of the path, selecting the one including; operating the robot repair unit to execute the second path; A method comprising. Claim 2 The step of selecting the second path includes: obtaining a predetermined polishing path; generating a surface appearance correction for the predetermined polishing path, wherein the generated surface appearance is generated based on a surface instruction obtained by a second imaging system; calculating the path length required to execute the surface appearance correction so that the surface correction is executed before the path reaches the end point; generating the second path by modifying the polishing path to include the surface appearance correction; The method according to claim 1, comprising. Claim 3 The surface appearance correction includes: a decrease in the rotational speed of the second polishing article while in contact with the surface; a decrease in the path speed of the second polishing article while in contact with the surface; a decrease in the random path speed of the second polishing article while in contact with the surface; the vibration rate of the second polishing article while in contact with the surface; the force applied to the second polishing article while in contact with the surface; the z-axis position of the arm end of the robot repair system relative to the surface, The method according to claim 2, selected from the group consisting of. Claim 4 The method according to claim 3, wherein before reaching the end point, the rotational speed, the orbital speed, the random orbital speed, or the vibration rate decreases to zero.

5. The method according to claim 3, wherein the applied force and / or the z-axis position decreases and the polishing article is separated from the surface before reaching the end point.

6. The method according to claim 1, wherein the second imaging system is the first imaging system.

7. The method according to claim 1, wherein the first imaging system is disposed on a robot arm of the robot repair system.

8. The method according to claim 1, wherein the first polishing article is a sanding disk and the second polishing article is a polishing pad.

9. A method for modifying the surface appearance of a reflective surface, comprising: contacting a polishing article with the reflective surface; moving the polishing article along the reflective surface, the moving comprising moving the polishing article by a robot arm from a starting point to an end point at a translational speed and a given force; including a method, wherein before reaching the end point, the moving speed with respect to the robot arm decreases at a rate exceeding 50%.

10. The method according to claim 9, wherein the moving speed is a rotational speed, an orbital speed, a random orbital speed, or a vibration speed.

11. The method according to claim 9 or 10, wherein the moving speed decreases at a rate exceeding 90%.

12. The method according to claim 9 or 10, wherein the moving speed decreases at a rate exceeding 95%.

13. The method according to claim 9 or 10, wherein the moving speed decreases at a rate exceeding 99%.

14. The method according to any one of claims 9 to 13, wherein before reaching the end point, the effective force applied to the polishing article by the robot arm decreases at a rate exceeding 50%.

15. The method according to claim 14, wherein the effective force is the applied force generated by a force control unit.

16. The method according to claim 14, wherein the effective force is generated by a change in the position of the robot arm with respect to the reflective surface.

17. The method according to any one of claims 14 to 16, wherein the effective force decreases at a rate exceeding 90%.

18. The method according to any one of claims 14 to 16, wherein the effective force value decreases to a negative value.

19. A method for modifying the surface appearance of a reflective surface, comprising: bringing the polishing article into contact with the reflective surface; moving the polishing article along the reflective surface, the moving including moving the polishing article by a robot arm from a starting point to an ending point at a translational speed and a given force; and a method in which, before reaching the ending point, the effective force applied to the polishing article by the robot arm decreases at a rate exceeding 50%.

20. The method according to claim 19, wherein the effective force is a force generated by a force control unit.

21. The method according to claim 19, wherein the effective force is generated by a change in the position of the robot arm with respect to the reflective surface.

22. The method according to any one of claims 19 to 21, wherein the effective force decreases at a rate exceeding 90%.

23. The method according to any one of claims 19 to 21, wherein the effective force value decreases to a negative value.

24. The method according to any one of claims 19 to 21, wherein the effective force decreases to less than 5 Newtons.

25. The method according to any one of claims 19 to 24, wherein, before reaching the ending point, the relative speed of the polishing article with respect to the robot arm decreases at a rate exceeding 50%.

26. The method according to claim 25, wherein the moving speed is a rotational speed, an orbital speed, a random orbital speed, or a vibration speed.

27. The method according to claim 25, wherein the moving speed decreases at a rate exceeding 90%.

28. The method according to claim 25, wherein the moving speed decreases at a rate exceeding 95%.

29. The method according to claim 25, wherein the moving speed decreases at a rate exceeding 99%.

30. A system for polishing a surface, comprising: a robot arm having an end effector at an end thereof, the end effector being configured to be coupled to a polishing article; a moving mechanism for moving the robot arm relative to the surface; a robot controller for controlling the robot arm to execute a polishing track on the surface, the polishing track including the polishing article in a state of contacting the surface, and the robot controller An orbit acquisition unit that acquires a polishing orbit, wherein the polishing orbit includes a surface appearance portion before the end point, and the surface appearance portion includes a decrease in the relative movement speed between the robot arm and the polishing article or a decrease in the effective force applied to the polishing article, the orbit acquisition unit; A command generation unit that transmits the polishing orbit to the movement mechanism to execute the orbit; A robot controller having the above; A system including the above.

31. The surface appearance orbit is generated by an orbit generation unit, and the orbit generation unit includes: A predetermined orbit acquisition unit that acquires a predetermined orbit; A surface appearance tolerance range acquisition unit that acquires a surface appearance tolerance range, wherein the surface appearance tolerance range includes an allowable haze threshold value, the surface appearance tolerance range acquisition unit; An orbit correction unit that applies an orbit correction to the predetermined orbit based on the surface appearance tolerance range, wherein the corrected predetermined orbit is the polishing orbit, the orbit correction unit; The system according to claim 30, including the above.

32. The system according to claim 30 or 31, wherein the orbit correction is a change in the z-axis position of the end of the robot arm with respect to the surface.

33. The system according to any one of claims 30 to 32, wherein the system further includes a force control unit, and the orbit correction is a decrease in the force to which the orbit correction is applied.

34. The system according to any one of claims 30 to 33, wherein the end effector is configured to rotate the polishing article while the polishing article is in contact with the surface, and the orbit correction is to decrease the rotation speed of the polishing article while it is in contact with the surface.

35. The system according to any one of claims 30 to 34, wherein the end effector is configured to move the polishing article in an orbital motion while the polishing article is in contact with the surface, and the orbit correction is to decrease the orbital speed of the polishing article while it is in contact with the surface.

36. The system according to any one of claims 30 to 35, wherein the end effector is configured to move the polishing article in a random orbital motion while the polishing article is in contact with the surface, and the orbit correction is to decrease the random orbital speed of the polishing article while it is in contact with the surface.

37. The system according to any one of claims 30 to 36, wherein the end effector is configured to vibrate the polishing article while the polishing article is in contact with the surface, and the trajectory correction is to decrease the vibration frequency of the polishing article while it is in contact with the surface.

38. The system according to any one of claims 30 to 37, wherein the end effector is configured to translate the polishing article along the surface, and the trajectory correction is a decrease in the translation speed.

39. The system according to any one of claims 30 to 38, wherein the controller further comprises a cycle time acquisition unit that acquires a predetermined cycle time of the predetermined trajectory, and the corrected trajectory is within a cycle time tolerance range of the predetermined trajectory.

40. The predetermined trajectory is obtained based on a surface analysis of the surface, the polishing trajectory is a second polishing trajectory, and the system a surface imaging system that images the surface after a first polishing operation is completed on a first polishing trajectory; a surface analyzer that generates a surface indication based on the surface imaging; further includes The system according to any one of claims 30 to 39, wherein the trajectory correction is performed based on the surface indication.

Images