Tooled device for robotic paint repair

Abstract

A robotic paint restoration system is disclosed. The system may optionally include a robotic arm, a first tooling system, and a fluid removal tool. The first tooling system may include a first end effector coupled to a first tool configured to contact a work piece and perform a surface modification on the work piece. The first end effector may be configured to actuate the first tool about a first axis to perform a surface modification on the work piece. The fluid removal tool may include a wiping medium. The fluid removal tool may be coupled to the robotic arm. The fluid removal tool may be configured to actuate the wiping medium about or along a second axis to remove fluid from the work piece. The first axis may be offset from the second axis, and the first axis may be within 45 degrees of being parallel to the second axis.

Description

Priority claim

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 201,750, filed May 11, 2021, the contents of which are incorporated herein by reference in their entirety. [Technical Field]

[0002] The present disclosure relates to surface modification and wiping tools, and more particularly to robotic repair using surface modification and wiping tools. [Background technology]

[0003] In the automotive industry, it is often necessary to prepare the surfaces of vehicle parts and replacement parts (e.g., bumpers) for various purposes (e.g., painting) or to repair the surfaces of vehicle parts and replacement parts due to defects introduced during painting or coating. Typical surface preparation processes include, for example, physical surface modification or "scuffing" of the vehicle surface. Typical repair operations often include surface modifications such as sanding or polishing. Different tools, materials, and fluids are used for surface preparation and repair of surface defects.

[0004] In the automotive industry, clearcoat repair is not automated in the automotive original equipment manufacturer (OEM) or aftermarket sectors. Technology to automate this process, as well as other paint applications that are amenable to abrasive and robotic inspection and repair (e.g., primer polishing, clearcoat defect removal, clearcoat polishing, etc.), is desirable. Summary of the Invention

[0005] Various examples are described herein to introduce in a simplified form a selection of concepts that are more fully described in the Detailed Description. The Abstract is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0006] This disclosure describes systems, apparatus, methods, and techniques related to various problems of automating defect-specific repair for paint applications. In current processes, humans manually wipe the surface of a workpiece after each surface modification step, which is time-consuming. The process time for automated paint repairs could be improved by streamlining or automating the fluid removal process step. However, no automated technology has been developed for wiping off residues after surface modification (e.g., after sanding or polishing). The present inventors have invented systems, apparatus, methods, and techniques that enable automated wiping of workpieces. Furthermore, the present inventors have recognized that the transition time between sanding and wiping, or between sanding and wiping, can be improved. For example, the present inventors propose that the working axis of the wiping medium be mounted substantially parallel to the working axis of the sanding or polishing tool. This eliminates the need to reorient the wrist of a robotic arm to transition between sanding and wiping, or between polishing and wiping, potentially reducing transition time and increasing production line throughput. Therefore, production line throughput can be improved.

[0007] The inventors further recognized that mounting the wiping media substantially parallel to the abrasive or polishing tool reduces the likelihood of these tools interfering with or colliding with other objects, such as work pieces, because reorienting the wiping media around an axis to reorient the wiping media for wiping after abrading or polishing is not required. The details of one or more examples of the present disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the present disclosure will be apparent from the description, drawings, and claims.

[0008] The disclosure contained herein includes, but is not limited to, the following illustrative examples. Example 1 is a robotic paint restoration system that optionally includes a robotic arm, a first tooling system, and a fluid removal tool. The first tooling system can include a first end effector coupled to a first tool configured to contact a work piece and perform a surface modification on the work piece. The first end effector can be configured to actuate the first tool about a first axis to perform a surface modification on the work piece. The fluid removal tool can include a wiping medium. The fluid removal tool can be coupled to the robotic arm. The fluid removal tool can be configured to actuate the wiping medium about or along a second axis to remove fluid from the work piece. The first axis can be offset from the second axis, and the first axis can be parallel to the second axis within 45 degrees.

[0009] Example 2 is the robotic paint repair system of example 1, wherein the first axis and the second axis can be oriented within 5 degrees of parallel.

[0010] Example 3 is the robotic paint repair system of any of Examples 1 and 2, wherein the first tooling system can be coupled to the robotic arm offset from the fluid removal tool.

[0011] Example 4 is the robotic paint repair system of any one of Examples 1-3, optionally further comprising a second tooling system. The second tooling system can include a second end effector coupled to a second tool configured to contact a work piece. The second tooling system can be coupled to the robot arm.

[0012] Example 5 is the robotic paint repair system of example 4, wherein the first tool and the second tool can be spaced apart on the robot arm within a range of 90 degrees or more and 180 degrees or less.

[0013] Example 6 is the robotic paint repair system of any one of Examples 4-5, wherein the fluid removal tool, the first end effector, and the second end effector can be attached to the same force control device.

[0014] Example 7 is the robotic paint restoration system of any one of Examples 1-6, wherein the wiping medium can be axially extendable along a second axis relative to the first tool.

[0015] Example 8 is the robotic paint repair system of any one of Examples 1 to 7, wherein the surface modification of the work piece can include any one of sanding, polishing, or buffing.

[0016] Example 9 is the robotic paint repair system of any one of Examples 1-8, wherein the first tooling system, along with the fluid removal tool, can be coupled to the robot arm via a flange. The flange can constrain the rotational orientation between the first tool that performs the surface modification on the work piece and the wiping medium that removes the fluid from the work piece.

[0017] Example 10 is the robotic repair system of any one of Examples 1-8, wherein the first tooling system, along with the fluid removal tool, can be coupled to the robot arm via a flange, the flange allowing limited rotational orientation between the first tool that performs surface modification on the work piece and the wiping medium that removes fluid from the work piece.

[0018] Example 11 is the robotic paint repair system of any one of Examples 1-3 and 7-10, wherein the first tooling system can be coupled to the second robotic arm.

[0019] Example 12 is the robotic paint repair system of any one of Examples 1-11, wherein the fluid can include an abrasive slurry.

[0020] Example 13 is the robotic paint repair system of any one of Examples 1-12, wherein the fluid removal tool and the first end effector can be attached to the same force control device.

[0021] Example 14 is a robotic paint restoration system that can include a robotic arm, a first tooling system, a second tooling system, and a fluid removal tool. The first tooling system can include a first end effector coupled to a first tool configured to contact a work piece and perform a first surface modification on the work piece. The first end effector can be configured to actuate the first tool about a first axis to perform the first surface modification on the work piece. The second tooling system can include a second end effector coupled to a second tool configured to contact the work piece. The fluid removal tool can include a wiping medium. The fluid removal tool can be coupled to the robotic arm. The fluid removal tool can be configured to actuate the wiping medium about or along a second axis to remove fluid from the work piece. The first axis can be offset from and substantially parallel to the second axis.

[0022] Example 15 is the robotic paint repair system of Example 14, wherein the first tool and the second tool can be coupled to the robot arm via the same force controller. The second tool can be configured to perform either a second surface modification of the work piece or a second fluid removal from the work piece.

[0023] Example 16 is the robotic paint restoration system of any one of Examples 14-15, wherein the wiping medium can be axially extendable along a second axis relative to the first tool or the second tool.

[0024] Example 17 is the robotic paint repair system of any one of Examples 14 to 16, wherein the first tool system, together with the fluid removal tool, is coupled to the robot arm via a flange, and the flange can prevent a change in rotational orientation between the first tool that performs the first surface modification on the workpiece and the wiping medium that removes the fluid from the workpiece.

[0025] Example 18 is the robotic paint repair system of any one of Examples 14-17, wherein at least one of the first tooling system and the second tooling system can be coupled to a second robotic arm.

[0026] Example 19 is the robotic repair system of any one of Examples 14-18, wherein the first axis and the second axis can be oriented within 5 degrees of parallel.

[0027] Example 20 is a method for performing automated paint repair on a work piece, the method optionally including: actuating a first tool attached to a robotic arm to perform a surface modification on the work piece, moving the tool to wipe the work piece without manipulating a wrist rotation axis of the robotic arm, and wiping the work piece using the tool.

[0028] Example 21 is the method of example 20, wherein the surface modification of the work piece can include any of sanding, polishing, or buffing.

[0029] Example 22 is the method of any one of Examples 20-21, optionally including: reorienting the wrist about the axis of rotation; and, after wiping the workpiece, actuating a second tool attached via the wrist of the robot arm to buff the workpiece.

[0030] Example 23 is the method of any one of Examples 20 to 21, and can optionally include: after wiping the work object, operating the second tool to buff the work object, and after buffing the work object, wiping the work object.

[0031] Example 24 is the method of any one of Examples 20 to 23, wherein the surface modification of the workpiece with the first tool is performed around a first axis, and wiping of the workpiece after surface modification of the workpiece is performed around or along a second axis, and the first axis can be offset from and substantially parallel to the second axis.

[0032] Example 25 is the method of example 24, wherein the first axis and the second axis can be oriented within 5 degrees of parallel.

[0033] Example 26 is the method of any one of Examples 20-25, optionally including: extending or retracting a wiping solution configured to wipe axially along a second axis relative to the first tool.

[0034] Example 27 is a method for performing automated paint repair on a work piece, the method optionally including the steps of: actuating a first tool attached to a robotic arm to perform a surface modification on the work piece, moving the tool to wipe the work piece while performing limited manipulation about a rotation axis of a wrist of the robotic arm, and wiping the work piece using the tool.

[0035] Example 28 is the method of example 27, wherein the limited manipulation of the wrist rotation axis can be in the range of 0.1 degrees to 45 degrees. [Brief explanation of the drawings]

[0036] [Figure 1] FIG. 1 is a schematic diagram illustrating an example system for robotic paint restoration using a paint restoration robot manipulating a surface modification tool and a wiping medium. [Figure 1A] FIG. 2 is a schematic diagram showing the paint restoration robot and surface modification tool and wiping media portions of the system of FIG. 1. [Figure 2] FIG. 1 is a schematic diagram illustrating portions of another robotic paint restoration system including an abrasive tool, wiping media, and portions of a paint restoration robot that manipulates the abrasive tool. [Figure 3] FIG. 1 is a schematic diagram of a dual parallel mounted end effector system for a paint restoration robot. [Figure 3A] FIG. 1 is a schematic diagram of a triple-mounted end effector system for a paint restoration robot. [Figure 4A] 4B is a view of the triple-mounted end effector system of FIG. 3A from a different perspective than FIG. 4B, showing the wiping media in a retracted position. [Figure 4B] 4A is a view of the triple-mounted end effector system of FIG. 3A from a different perspective than FIG. 4A, showing the wiping media in a retracted position. [Figure 5A] 5B is a view of the triple-mounted end effector system of FIG. 3A from a different perspective than FIG. 5B, showing the wiping medium in a deployed position. [Figure 5B] 5A is a view of the triple-mounted end effector system of FIG. 3A from a different perspective than FIG. 5A, showing the wiping medium in a deployed position. [Figure 6] FIG. 1 is a schematic diagram of a robotic repair system. [Figure 7] FIG. 1 is a flow diagram of a method for performing automated paint repair on a workpiece.

[0037] In the drawings, like reference numerals refer to like elements. The above-identified drawings, which may not be drawn to scale, illustrate various embodiments of the present disclosure. Other embodiments are contemplated, as described in the detailed description. This disclosure describes the presently disclosed disclosure by way of representation and not solely by way of depicted examples. It should be understood that many other variations and embodiments devised by those skilled in the art are within the scope and spirit of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0038] The present disclosure provides an automated system and method that uses a robotic repair unit with a tool attached to the end of an arm for surface modification of an object surface. The automated system and method also enable debris removal at the end of the arm. This is accomplished by a debris removal tool used before, after, or during surface modification. As previously discussed, wiping media may be mounted substantially parallel to one or more of the tools performing the surface modification. This arrangement eliminates the need for additional manipulation of the paint repair robot's wrist, thereby reducing processing time. The present application also recognizes other advantages, such as reduced part count (a single force control unit can be used for both wiping and surface modification) and reduced potential for interference or collision with other objects, such as workpieces.

[0039] The processing tool and fluid removal tool are attached to an end effector at the tip of a moving robot arm and can move as a unit between various regions of a workpiece. The surface modification tool may include a functional part that contacts and prepares the surface of an object and one or more sensors for detecting work status information of the end effector tool. The end effector may include a dispenser as part of the wiping tool or surface modification tool that dispenses fluid while the functional part contacts and prepares the surface of the object. The various sensors may also include force sensors used in conjunction with processing.

[0040] It should be understood that, although example implementations of one or more embodiments are provided below, the disclosed systems and / or methods described with respect to Figures 1-7 may be implemented using any number of technologies, whether currently known or in existence. This disclosure should not be limited in any way by the example implementations, drawings, and technologies shown below, including the exemplary designs and implementations described herein, and may be modified within the scope of the appended claims and their full scope of equivalents.

[0041] When the term "about an axis of actuation" or "axis of actuation" or similar terms are used, it can mean rotary actuation, orbital actuation, or random orbital actuation. The term "along an axis of actuation" or "axis of actuation" or similar terms means linear actuation. The term "fluid" as used herein means any or combination of a pure fluid, a fluid combined with particulates such as a slurry, debris from surface modification, or the like. The term "surface modification" or similar terms includes surface repair, scraping, rubbing, sanding, polishing, buffing, and the like. The term "substantially parallel" refers to a range including within 5 degrees of parallel (i.e., including from exactly parallel to an angle of 5 degrees from exactly parallel). The term "limited rotational direction change" or "limited operation about an axis of rotation" or similar terms can mean a rotational direction change ranging from 0.1 degrees to 45 degrees.

[0042] In one embodiment, the functions or algorithms described herein may be implemented in software. Software may consist of computer-executable instructions stored in one or more local or networked non-transitory memories or other types of hardware-based storage devices. Furthermore, such functions may correspond to modules that are software, hardware, firmware, or any combination thereof. Functions may be implemented in one or more modules if desired, and the embodiments described herein are merely examples. Software may be implemented in digital signal processors, ASICs, microprocessors, or other types of processors that run on computer systems, such as personal computers, servers, or other computer systems, and turn such computer systems into machines that incorporate specific programs.

[0043] 1 is a schematic diagram of a robotic paint repair system 100. System 100 may include a vision inspection system (not shown) and a defect repair system 101. Each system may include subunits such as a robotic repair unit 102A including a robotic arm 104A and a robotic repair unit 102B including a robotic arm 104B. The system is controlled by a motion controller, which may receive instructions from one or more application controllers 150. The application controllers may receive input from and provide output to a user interface 160.

[0044] The robotic repair unit 102A includes a force control unit 124A aligned with the end effector 126A. The robotic repair unit 102B includes a force control unit 124B aligned with the end effector 126B. As shown in FIG. 1 , the force control unit 124A is coupled to the end effector 126A and coupled to the tool 128A. The force control unit 124B is coupled to the end effector 126B and coupled to the tool 128B. The tools 128A and / or 128B may be arranged in one embodiment as described in U.S. Provisional Patent Applications Serial Nos. 62 / 940950 and 62 / 940960, filed November 2, 2019, although other arrangements are expressly contemplated. The visual inspection unit detects defects in the vehicle surface 130, which may then be repaired by the defect repair system 101.

[0045] The robotic repair units 102A and / or 102B may have a base fixed to a rail system that moves with the vehicle being repaired, or may be mounted on a carrier in a wall or ceiling. Depending on the location of the defect, the robotic repair units 102A and / or 102B may need to move closer to or further from the vehicle, or higher or lower relative to the vehicle. A movable base may facilitate repair of hard-to-reach defects.

[0046] 1 has a Cartesian coordinate system shown for reference, with an x-axis, a y-axis, and a z-axis. It is recognized that in some examples, the robotic repair unit 102B is not offset from the vehicle in the y-axis relative to the robotic repair unit 102A. Rather, the robotic repair unit 102B may be located on the same side as the robotic repair unit 102A, offset in the z-axis, for example. The positions of the tools 128A and 128B may change due to the operation of the respective robotic repair units 102A and / or 102B or as a result of other actuators.

[0047] FIG. 1A is a schematic diagram showing portions of robotic repair units 102A and 102B. As shown in FIG. 1A, robotic arms 104A and / or 104B can move in six dimensions, i.e., translation or rotation, about the x-axis, y-axis, and / or z-axis. Robotic repair unit 102A includes a force control unit 124A and an end effector 126A with one or more tools 128A that can interact with a work surface, such as vehicle surface 130 (FIG. 1). In one embodiment, tool 128A may include a backup pad or other suitable abrasive tool. During a sanding operation, tool 128A may have an abrasive disc or other suitable abrasive article attached thereto using adhesive, a hook-and-loop, a clip system, a vacuum, or other suitable attachment system. A tool 128A attached to the robotic repair unit 102A has the ability to determine its position within the degrees of freedom provided by the robotic repair unit 102A (in most cases six degrees of freedom) and may have other degrees of freedom within its reference frame (e.g., a compliant force control 124A unit).

[0048] FIG. 1A further illustrates that the robotic repair unit 102B includes a force control unit 124A and an end effector 126B, and includes one or more tools 128A capable of interacting with a work surface, such as a vehicle surface 130 (FIG. 1). The tools 128A and 128B may be mounted such that they share substantially parallel actuation axes A1 and B1, respectively. Stated differently, the tool 128A may have a first axis A1 configured to perform surface modification on the work surface, and the tool 128B may have a second axis B1 configured to contact and wipe the work surface. The first axis A1 may be offset from the second axis B1 in any combination of the x-axis, y-axis, and / or z-axis directions. However, the first axis A1 may be positioned substantially parallel to the second axis B1 (within 5 degrees of parallelism) and may be positioned substantially parallel to the second axis B1.

[0049] Tool 128B may include wiping medium 130B (also referred to herein as a wiping solution). Wiping medium 130B may be, for example, a cloth, sponge, or other medium that can be pressed linearly against the workpiece along second axis B1 or dragged along the workpiece in rotation along second axis B1 to remove fluids and other residues from the workpiece. While the current tool 128B is shown as a removal tool using a cloth or other medium, in other embodiments, it could be other types of tools, including moving systems such as vacuums or air knives. Similarly, the systems and methods described herein are described with respect to linear, unidirectional wiping processes, but more complex motions, such as rotary, orbital, or random orbital devices, are expressly excluded.

[0050] During the painting or clearcoat repair process, fluids may be dispersed onto the workpiece before, during, or after application of 128A. This process fluid may combine with particulates from the process to form a slurry. The particulates that make up this slurry are typically caused by the sanding process, which occurs before the abrasive buffing step. Processing with tool 128A without first removing this slurry can have adverse effects on the final painted surface. These adverse effects may include a cloudy or un-buffed appearance, or undesirable scratches or other damage to the final painted product, which may be caused by micro-blemishes. The improvement when removing the slurry is unexpected, and robotic repair systems do not have a standard for removing the slurry before surface buffing. While the cloudy or imperfect appearance is not observed on all buffed surfaces, it is most noticeable after the accumulation of slurry and particulates on the buffing pad due to sanding. The adverse effects of the buildup on the buffing pad were demonstrated in experiments performed on clearcoat workpieces.

[0051] 2 shows a schematic diagram of a system 200 including multiple robotic repair units 202A, 202B, and 202C, which may be positioned along a vehicle. Each of the robotic repair units 202A, 202B, and 202C includes an arm 204A, 204B, and 204C, a force control unit 224A, 224B, and 224C, an end effector 226A, 226B, and 226C, and a tool 228A, 228B, and 228C, respectively. The system 200 may be constructed in the manner previously described, but may include separate robotic repair units 202A, 202B, and 202C for operation of each of the tools 228A, 228B, and 228C. Tool 228A may be an abrasive tool, such as a polishing pad, configured for polishing a workpiece (vehicle surface). Tool 228B may be a wiping medium as previously described. Tool 228C may be an abrasive tool, such as an abrasive pad configured for polishing or buffing a work piece.

[0052] 2 shows that a first axis A2 of actuation of tool 228A is substantially parallel to a second axis B2 of actuation of tool 228B. The first axis A2 may be offset from the second axis B2. Similarly, the second axis B2 of actuation of tool 228A may be substantially parallel to a third axis C2 of actuation of third tool 228C. The second axis B2 may be offset from the third axis C2.

[0053] FIG. 3 illustrates a dual-mounted end effector system 300 mounted on a robotic arm 304. The robotic arm 304 can move the end effector system 300 through various motions by rotating it using a mounting adapter plate or wrist 310 and moving it vertically using a joint 315. The first end effector 320A is configured to actuate a first surface modification tool 330 along a first actuation axis A3. The second end effector 320B is configured to actuate a wiping medium 340 along or about a second actuation axis B3. In some embodiments, the robotic arm 304 can move to position the first tool 330 or the wiping medium 340 to interact with a workpiece. However, such movement does not require rotation of the mounting adapter plate or wrist 310 about the x-axis, y-axis, or z-axis. Instead, such rotational movement may be limited to a range of, for example, 45 degrees, 35 degrees, 25 degrees, 15 degrees, 10 degrees, or less. The illustrated system 300 can alternately manipulate a first tool 330 and wiping media 340 using a single force control unit 324 attached to a mounting adapter plate or wrist 310. The first tool 330 may be offset from, but substantially parallel to, the wiping media 340 about its actuation axis B3. The force control unit 324 may be used for both the first end effector 320A and first tool 330 and the second end effector 320B and wiping media 340.

[0054] The first tool 330 may be used for polishing, sanding, or other surface preparation purposes. The first tool 330 may be offset from the wiping media 340, for example, along one or more of the x-axis, y-axis, or z-axis of a Cartesian coordinate system. The wiping media 340 may be used to remove fluids and residues, as previously discussed. The end effectors 320A and / or 320B may be pneumatically, servo-, hydraulically, or configured to operate in other known manners. The wiping media 340 may incorporate a spring or pneumatic compliance source to allow compliance when pressure or force is applied. Alternatively, the wiping media 340 may be attached using the same compliant tool to which the first tool 330 is attached.

[0055] FIG. 3A illustrates a triple-mounted end effector system 400 mounted on a robotic arm 404. The robotic arm 404 can move the end effector system 400 through various motions by rotating it using a mounting adapter plate or wrist 410 and moving it vertically using a joint 415. A first end effector 420A is configured to actuate a first surface modification tool 430 configured for sanding along a first actuation axis A4. A second end effector 420B is configured to actuate a wiping medium 340 along or about a second actuation axis B4. In some embodiments, the robotic arm 404 can move to position the first tool 430 or the wiping medium 440 to interact with a workpiece. However, such movement does not require rotation of the mounting adapter plate or wrist 410 about the x-, y-, and z-axes. Instead, such rotational motion may be limited to a range of, for example, 45 degrees or less. The third end effector 420C is configured to actuate a second surface modification tool 450 configured for polishing along a third actuation axis C4. The illustrated system 400 can alternately operate the first tool 430, the second tool 450, and the wiping medium 440 using a single force control unit 424 attached to the plate 410. The first tool 430 may be offset from, but substantially parallel to, the wiping medium 440 about its actuation axis B4. The force control unit 424 may be used for both the first end effector 420A and the first tool 430, the second end effector 420B and the wiping medium 440, and the third end effector 420C and the second tool 450. Alternatively, the second end effector 420B for the wiping medium 440 may incorporate a spring or pneumatic compliance source to allow compliance when pressure or force is applied. As shown, the wiping media 440 may be attached using the same compliant tool to which the first tool 430 is attached.

[0056] While the second tool 450 is configured for buffing a workpiece, the second tool 450 could also be a second tool (similar to the first tool) configured for sanding. Alternatively, the first and second tools 430 and 450 could be configured for buffing. Additionally, other possible combinations and sequences of the two tools 430 and 450 are also contemplated. For example, the second tool 450 could be configured as a wiping medium, as a further example. Alternatively, a second wiping medium could be included as part of the end effector system 400. This second wiping medium could be offset from and substantially parallel to the axis C4 of the second tool 450, for example.

[0057] The first tool 430 may be offset from the wiping media 440, for example, with respect to one or more of the x-axis, y-axis, or z-axis of a Cartesian coordinate system. The second tool 450 may be mounted opposite the first tool 430 such that rotating the wrist 410 brings the second tool 450 into a surface modification position. However, it is contemplated that the second tool 450 may be offset or oriented less than 180 degrees, for example, in the range of 90 degrees to 180 degrees, according to other examples.

[0058] 4A and 4B show views of a triple-mounted end effector system 400 including a mounting adapter plate or wrist 410, a force control unit 424, a first end effector 420A, a second end effector 420B, and a third end effector 420C, a first tool 430, a wiping medium 440, and a second tool 450. Axes A4, B4, and C4 are also shown. FIG. 4B further illustrates that the first tool 430 is offset from the wiping medium 440 with respect to one or more of the x-, y-, or z-axes of a Cartesian coordinate system, for example. However, the first actuation axis A4 of at least the first end effector 420A and first tool 430 is substantially parallel to the second actuation axis B4 of the wiping medium 440 of the second end effector 420B. 4A and 4B show the second end effector 420B and wiping medium 440 in a retracted position to provide clearance for grinding against the first tool 430 and reduce the possibility of interference.

[0059] 5A and 5B show the triple-mounted end effector system 400 with the second end effector 420B and wiping medium 440 in an extended position relative to the first tool 330 to provide clearance for the wiping medium 440 to remove slurry and fluids from the work piece and reduce the possibility of interference.

[0060] 6 shows a schematic diagram of a robotic repair system 500. The robotic repair system 500 may be useful in accordance with embodiments described herein for sanding and polishing defects on a work surface. The work surface may, in some embodiments, be a vehicle such as an automobile, car, truck, boat, airplane, helicopter, etc.

[0061] In one embodiment, the robotic repair system 500 includes an optical sensor 504, which may be used to locate paint / clearcoat flaws and areas requiring repair. The robotic repair system 500 may include a robotic movement mechanism 508, which is used to move the arm tip assembly near the defective repair area. As shown in FIG. 6 , in one embodiment, the robotic repair system 500 includes a controller 530 that controls the movement and sensing of the robotic arm 510 and associated components. However, in some embodiments, it is expressly contemplated that the robotic arm 510 and / or components mounted thereon have their own controllers and receive and execute movement and sensing commands from the controller 530.

[0062] In some embodiments, the end of the robotic arm 510 may include an end-of-arm assembly that includes various tools, as in the examples shown in the previous figures, but it is expressly contemplated that in other embodiments, some components may be located elsewhere on one or more of the operating robotic arms 510, as shown in FIG.

[0063] The first polishing tool 542 may be attached to the robot arm 510. In some embodiments, the first polishing tool may be coupled to the first end effector 540. In some embodiments, the second polishing tool 548 may be attached to the robot arm 510. The second tool 548 may be coupled to the second end effector 546. The fluid removal mechanism 560 may be attached to the robot arm 510. However, in some embodiments, it is expressly contemplated that some of these components are attached to multiple robot arms 510. For example, the first robot arm 510 may support the first polishing tool 542 (e.g., a polishing robot with a polishing tool), and the second robot arm 510 may support a second polishing tool (e.g., a polishing robot with a polishing tool).

[0064] In one embodiment, the robot arm 510 is positioned by an arm movement mechanism 516. The polishing tools 542, 548 and fluid removal mechanism 560 may also be positioned by the arm movement mechanism 516 in one embodiment, but may each have their own movement mechanisms for positioning on the work surface.

[0065] The robotic arm 510 may also be provided with a force control unit 512 that controls the robotic arm 510, the end effector system, and its interaction with the work surface.

[0066] In some embodiments, an airline 514 and a fluid dispenser 526 feed from the robotic arm 510 to the end effector system, providing the air and fluid supplies necessary for the operation of the first tool 542 and the second tool 548 .

[0067] In some embodiments, a fluid removal tool 550 is also coupled to the force control unit 512. The fluid removal tool 550 may be, for example, a cloth-based wiping medium, an air knife, a vacuum system, or other suitable tool. However, in some embodiments, it is also contemplated that the fluid removal tool 550 may be coupled to a force control unit separate from the force control unit used for tool 542 or tool 548. In other embodiments, it is also contemplated that the fluid removal tool 550 may be a passive tool without a force control unit. In some embodiments, the fluid removal tool 550 is attached to the robotic arm 510 in a fixed position. In some embodiments, fasteners 552 are used to secure the fluid removal tool 550 in a position that allows passive wiping. The fasteners 552 may be stretchable in some embodiments or coupled to the force control unit 512 to facilitate semi-passive wiping.

[0068] The robotic arm 510 may also include a fluid removal compliance device 556. The fluid removal compliance device 556 may provide force compliance for the fluid removal compliance device 556. The fluid removal compliance device 556 may be a passive compliance device, such as a flexible or compressible material that forces the wiping media toward the work surface. In other embodiments, the fluid removal compliance device 556 is a mechanical device, such as a mechanical spring or a pneumatic cylinder.

[0069] In some embodiments, the fluid removal tool 550 may be moved through space using a fluid removal movement mechanism 554. The movement mechanism 554 controls variables such as pitch, tilt, and yaw of the active wiping action of the fluid removal tool 550.

[0070] In some embodiments, the fluid removal tool 550 may function in conjunction with a fluid removal force control unit 558. The force control unit 558 may maintain an appropriate force or pressure between the fluid removal tool 550 and the work piece. The fluid removal force control unit 558 may be attached to the robotic arm 510 and provide signals or controls to the fluid removal tool 550 through fasteners 552. In other embodiments, the pressure or tension on the work piece surface is adjusted by a fluid removal compliance device 556.

[0071] Fluid removal tool 550, in some embodiments, may function in conjunction with a fluid removal mechanism 560. Fluid removal mechanism 560 may be a pad, vacuum, brush, or scraper tool used to remove particulates, debris, fluid, or slurry from the wiping media of fluid removal tool 550. Fluid removal mechanism 560 may help provide a suitably absorbent and effective wiping media for multiple cleanings of a work surface.

[0072] In another embodiment, the fluid removal tool 550 may include a replaceable component, for example, for replacing a new absorbent pad when an old one becomes saturated with fluid or debris. The fluid removal replacement mechanism 562 may facilitate replacement of the wiping medium in the fluid removal tool 550. In some embodiments, the replacement mechanism 562 is a release clip, button, or hook and loop system used to quickly replace saturated or depleted wiping medium.

[0073] FIG. 7 illustrates a method 700 for performing automated paint repair on a work piece. The method may include step 702 of actuating a first tool attached to a robotic arm via a wrist to modify the surface of the work piece. The method may include step 804 of wiping the work piece after modifying the surface of the work piece. Wiping may be performed without manipulating the rotation axis of the wrist of the robotic arm, or by manipulating the wrist within a limited range (e.g., 0.1 degrees to 45 degrees) about the rotation axis. Optionally, surface modification of the work piece may include either sanding or buffing the work piece. Optionally, method 700 may include the steps of reorienting the wrist about the rotation axis after wiping the work piece and actuating a second tool attached to the robotic arm via a wrist to buff the work piece. Alternatively, method 700 may include the step of actuating a second tool after wiping the work piece to buff the work piece. Method 700 may optionally include wiping the work object after buffing. Method 700 may include surface modification of the work object with a first tool along a first axis and wiping the work object after surface modification along a second axis. The first axis is offset from the second axis and is substantially parallel (within 5 degrees of being completely parallel). In another example, the first and second axes are within 45 degrees of being parallel. Thus, the first and second axes may be at an angle of 45 degrees, 35 degrees, 25 degrees, 20 degrees, 15 degrees, 10 degrees, or less. Method 700 may include configuring the wiping solution to extend or retract the wiping solution axially relative to the first tool along the second axis.

[0074] In one or more examples, the functions described may be implemented by locally or remotely located hardware, software, firmware, or a combination thereof. If implemented in software, the functions may be stored on or transmitted over a computer-readable medium as one or more instructions or code executed by a hardware-based processing unit. Computer-readable media includes computer-readable storage media, which corresponds to tangible media such as data storage media or communication media, including any medium that facilitates transfer of a computer program from one place to another according to a communication protocol. In this manner, computer-readable media generally corresponds to (1) non-transitory tangible computer-readable storage media or (2) communication media such as signals or carrier waves. Data storage media are any available media that can be accessed by one or more computers or one or more processors to obtain instructions, code, and / or data structures for implementing the techniques described in this disclosure. A computer program product may include computer-readable media.

[0075] By way of example, and not limitation, such computer-readable media may include RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, flash memory, or any other medium that stores instructions or data structures in the form of desired program code and that can be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if instructions are transmitted from a website, server, or other remote source using coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, or microwave, the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, or microwave are included within the definition of media.

[0076] It should be understood, however, that computer-readable storage media and data storage media do not include connections, carrier waves, signals, or other transitory media, but instead are directed to non-transitory, tangible storage media. As used herein, disk and disk include compact disks (CDs), laser disks, optical disks, digital versatile disks (DVDs), floppy disks, Blu-ray disks, etc., where disks typically reproduce data magnetically and disks reproduce data optically using lasers. Combinations of the above should also be included within the scope of computer-readable media.

[0077] The instructions may be executed by one or more processors, such as one or more digital signal processors (DSPs), general-purpose microprocessors, application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other equivalent integrated or discrete logic circuitry, and any combination of such components. Accordingly, the term "processor," as used herein, may refer to any such structure or other structure suitable for implementing the techniques described herein. Moreover, in some aspects, the functionality described herein may be provided in dedicated hardware and / or software modules. The techniques may also be implemented entirely in one or more circuits or logic elements.

[0078] The techniques of this disclosure may be implemented in a wide variety of devices or apparatuses, such as wireless communication devices or handsets, microprocessors, integrated circuits (ICs), or sets of ICs (e.g., chipsets). To emphasize that a device is configured to perform the disclosed techniques, various components, modules, or units are described in this disclosure, but are not necessarily realized by different hardware units. Rather, as described above, various units may be combined in a hardware unit or provided by a collection of interoperable hardware units, including one or more processors.

[0079] The functions, techniques, or algorithms described herein may, in one example, be implemented in software. Software may consist of computer-executable instructions stored in one or more local or networked non-transitory memories or other types of hardware-based storage. Furthermore, such functions may correspond to modules that are software, hardware, firmware, or any combination thereof. Multiple functions may be performed in one or more modules if desired, and the examples described herein are merely illustrative. Software may be executed in a digital signal processor, ASIC, microprocessor, or other type of processor and may run on a computer system, such as a personal computer, server, or other computer system, transforming such a computer system into a machine with a particular program installed.

[0080] Various examples are described. These and other examples are within the scope of the following claims.

Claims

1. A robotic arm, a first tooling system including a first end effector coupled to a first tool configured to contact a work piece and perform a surface modification on the work piece, the first end effector configured to actuate the first tool about a first axis to perform the surface modification on the work piece; a fluid removal tool comprising a wiping medium, the fluid removal tool coupled to the robotic arm and configured to actuate the wiping medium about or along a second axis to remove fluid from the work piece; Equipped with 10. A robotic paint repair system, wherein the first axis is offset from the second axis, and the first axis is parallel to the second axis within 45 degrees.

2. The robotic paint restoration system of claim 1 , wherein the first axis and the second axis are substantially parallel and oriented no more than 5 degrees from parallel.

3. The robotic paint restoration system of claim 1 , wherein the first tooling system is coupled to the robotic arm offset from the fluid removal tool.

4. 10. The robotic paint restoration system of claim 1, further comprising a second tooling system coupled to the robotic arm, the second tooling system comprising a second end effector coupled to a second tool configured to contact the work piece.

5. 5. The robotic paint repair system of claim 4, wherein the first tool and the second tool are spaced apart on the robot arm within a range of 90 degrees or more and 180 degrees or less.

6. The robotic paint restoration system of claim 4 , wherein the fluid removal tool, the first end effector, and the second end effector are attached to the same force control device.

7. The robotic paint restoration system of claim 1 , wherein the wiping medium is axially extendable along the second axis relative to the first tool.

8. The robotic paint restoration system of claim 1 , wherein the surface modification of the workpiece includes one of sanding, polishing, or buffing the workpiece.

9. 2. The robotic paint restoration system of claim 1, wherein the first tool system, together with the fluid removal tool, is coupled to the robot arm via a flange, and the flange does not change the rotational orientation between the first tool that performs the surface modification on the workpiece and the wiping medium that removes fluid from the workpiece.

10. 2. The robotic paint restoration system of claim 1, wherein the first tool system, together with the fluid removal tool, is coupled to the robot arm via a flange, the flange providing limited rotational orientation between the first tool that performs the surface modification on the workpiece and the wiping medium that removes fluid from the workpiece.

11. The robotic paint restoration system of claim 1 , wherein the first tooling system is coupled to a second robotic arm.

12. The robotic paint restoration system of claim 1 , wherein the fluid comprises an abrasive slurry.

13. The robotic paint restoration system of any one of claims 1 to 12, wherein the fluid removal tool and the first end effector are attached to the same force control device.

14. A robotic arm, a first tooling system including a first end effector coupled to a first tool configured to contact a work piece and perform a first surface modification on the work piece, the first end effector configured to actuate the first tool about a first axis to perform the first surface modification on the work piece; a second tooling system including a second end effector coupled to a second tool configured to contact the workpiece; a fluid removal tool including a wiping medium, the wiping medium coupled to the robotic arm and configured to actuate the wiping medium about or along a second axis to remove fluid from the work piece; and Equipped with The robotic paint repair system, wherein the first axis is offset from and substantially parallel to the second axis.

15. 15. The robotic paint repair system of claim 14, wherein the first tool and the second tool are coupled to the robot arm via the same force control device, and the second tool is configured to perform either a second surface modification of the work piece or a second fluid removal from the work piece.

16. The robotic paint restoration system of claim 14 , wherein the wiping medium is axially extendable along the second axis relative to the first tool or the second tool.

17. 15. The robotic paint restoration system of claim 14, wherein the first tool system, together with the fluid removal tool, is coupled to the robot arm via a flange, and the flange does not change the rotational orientation between the first tool that performs the first surface modification on the workpiece and the wiping medium that removes fluid from the workpiece.

18. The robotic paint restoration system of claim 14 , wherein at least one of the first tooling system and the second tooling system is coupled to a second robotic arm.

19. 19. The robotic paint restoration system of claim 14, wherein the first axis and the second axis are oriented within 5 degrees of parallel.

20. A method for performing automatic paint repair on a work object, comprising: activating a first tool attached to a robotic arm to modify the surface of the workpiece; moving a tool configured to wipe the workpiece without manipulating a rotation axis of a wrist of the robot arm; wiping the work object using the tool; Including, A method in which the surface modification of the workpiece by the first tool is performed around a first axis, and the wiping of the workpiece after surface modification of the workpiece is performed around or along a second axis, the first axis being offset from and substantially parallel to the second axis.

21. 21. The method of claim 20, wherein the surface modification of the work piece includes any of grinding, polishing, or buffing the work piece.

22. A method for performing automated paint repair on a workpiece, comprising: activating a first tool attached to a robotic arm to modify the surface of the workpiece; moving a tool configured to wipe the workpiece without manipulating a rotation axis of a wrist of the robot arm; wiping the work object using the tool; Including, reorienting the wrist about an axis of rotation; After wiping the workpiece, actuating a second tool attached to the robot arm via the wrist to buff the workpiece; The method further comprises:

23. A method for performing automated paint repair on a workpiece, comprising: activating a first tool attached to a robotic arm to modify the surface of the workpiece; moving a tool configured to wipe the workpiece without manipulating a rotation axis of a wrist of the robot arm; wiping the work object using the tool; Including, activating a second tool to buff the workpiece after the wiping; wiping the workpiece after the buffing of the workpiece; The method further comprises:

24. 21. The method of claim 20, wherein the first axis and the second axis are oriented within 5 degrees of parallel.

25. 25. The method of any one of claims 20 to 24, further comprising axially extending or retracting a wiping medium configured to perform the wiping relative to the first tool along a second axis.

26. A method for performing automatic paint repair on a work object, comprising: activating a first tool attached to the robot arm to modify the surface of the work piece; a step of moving a tool for wiping the work object while performing limited manipulation of a rotation axis of a wrist of the robot arm; wiping the work object using the tool; Including, A method in which the surface modification of the workpiece by the first tool is performed around a first axis, and the wiping of the workpiece after surface modification of the workpiece is performed around or along a second axis, the first axis being offset from and substantially parallel to the second axis.

27. 27. The method of claim 26, wherein the limited manipulation of the wrist rotation axis is in the range of 0.1 degrees to 45 degrees.

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