Robotic repair system and method

Abstract

A fluid dispensing system for a robotic repair unit includes a fluid container. The system also includes a fluid dispenser associated with the robotic repair unit. The system also includes a fluid coupler connecting the polish container to the polish dispenser. The system also includes a mounting mechanism configured to couple the polish container to the robotic repair unit.

Description

[Background technology]

[0001] Clearcoat repair is one of the final operations to be automated in the automotive and vehicle original equipment manufacturing (OEM) sector. Techniques are desired to automate this process as well as other paint applications (e.g., primer sanding, clearcoat defect removal, clearcoat polishing, etc.) that are amenable to the use of abrasives and / or robotic inspection and repair.

[0002] Prior efforts to automate paint defect detection and repair include the system described in U.S. Patent Application Publication No. 2003 / 0139836, which discloses the use of electronic imaging to detect and repair paint defects on a vehicle body. This system compares vehicle imaging data with CAD data for the vehicle to generate three-dimensional paint defect location coordinates for each paint defect. These paint defect data (e.g., defect type, defect type, etc.) and paint defect location coordinates are used to develop a repair plan for automated repair using multiple automated robots that perform various tasks, including sanding and polishing the paint defects. [Brief explanation of the drawings]

[0003] The drawings, which are not necessarily drawn to scale, and in which like numerals may refer to like elements in different views, illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0004] [Figure 1] 1 is a schematic diagram of a robotic paint repair system in which embodiments of the present invention are useful;

[0005] [Figure 2A] FIG. 1 is a schematic diagram of a paint repair robot that may be useful in embodiments of the present invention. [Figure 2B]FIG. 1 is a schematic diagram of a paint repair robot that may be useful in embodiments of the present invention.

[0006] [Figure 3] 10A-10C illustrate different configurations of a self-contained fluid distribution system according to embodiments herein. [Figure 4] 10A-10C illustrate different configurations of a self-contained fluid distribution system according to embodiments herein. [Figure 5] 10A-10C illustrate different configurations of a self-contained fluid distribution system according to embodiments herein. [Figure 6] 10A-10C illustrate different configurations of a self-contained fluid distribution system according to embodiments herein.

[0007] [Figure 7] 1 illustrates an automatic dispenser according to some embodiments herein.

[0008] [Figure 8] 1 illustrates a method of using a self-contained fluid distribution system according to embodiments herein.

[0009] [Figure 9] 1 illustrates a method for replacing a component of a self-contained fluid distribution system according to an embodiment herein.

[0010] [Figure 10] 1 illustrates a robotic repair unit, according to embodiments herein.

[0011] [Figure 11] 1 illustrates a replacement kit for a self-contained fluid distribution system according to an embodiment herein. DETAILED DESCRIPTION OF THE INVENTION

[0012] Recent advances in imaging technology and computing systems have made the process of clearcoat inspection feasible at production speeds. Specifically, stereo deflectometry has recently been shown to be capable of providing images and locations of paint and clearcoat defects with adequate resolution, along with spatial information (providing coordinate location information and defect classification) to enable subsequent automated spot repair.

[0013] Improvements in defect detection and classification technology enable the ability to automate the repair of detected defects. Automated repair processes present new challenges, including supplying materials, such as abrasive articles for sanding or polishing, fluids, such as water for wet sanding or polishing, and removing used materials and waste from the vehicle surface. Several solutions for supplying fluids to the repair area are described herein. Automated repair can benefit from fluids dispensed on or near the detected defect area. However, paint spraying uses large volumes, requiring longer pressurized lines extending from the source to the dispenser, while defect repair uses fluids in much smaller quantities. When smaller volumes of fluid are used, the presence of long fluid lines and dedicated machinery increases the likelihood that the fluid will remain in the lines and dry out, causing clogs. Long lines also generate waste and require solvents for cleaning and dedicated pumps to apply pressure and force the fluid through the lines. Additionally, some polishing agents can thicken, agglomerate, or solidify upon contact with certain metals. In automated robotic repair units, a solution for using small amounts of fluid is desired.

[0014] As used herein, the term "vehicle" is intended to encompass a wide variety of mobile structures that are coated with at least one paint or clear coat 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, boats (with or without motors), airplanes, helicopters, motorcycles, and the like.

[0015] As used herein, the term "robotic repair unit" refers to a robotic repair system that interacts with a surface to remove defects. In some embodiments, the robotic repair unit may be a fixed unit that operates on a stationary surface. In other embodiments, the robotic repair unit is a mobile repair unit that can move along rails, tracks, or other mechanisms to address defects on a moving surface. The robotic repair unit may have one or more end effectors with one or more tools, such as those described in U.S. Provisional Patent Application Nos. 62 / 940950, filed November 2, 2019, and 62 / 940960, filed November 2, 2019. However, other robotic repair unit configurations are also expressly contemplated.

[0016] Paint repair is one of the last remaining steps in the vehicle manufacturing process that remains largely manual. Historically, this has been due to two main factors: a lack of sufficient automated inspection and the difficulty of automating the repair process itself.

[0017] Progress has been made on the problem of polishing a surface to inspect parts and to address defects in a visually acceptable manner, as described in U.S. Provisional Patent Application No. 62 / 941,286, filed November 27, 2019. However, as automation advances, additional problems arise, including how to deliver (dispense) the abrasive material, including the abrasive article, and the fluids required for the polishing process, and how to remove or replace used abrasive material from the surface.

[0018] FIG. 1 is a schematic diagram of a robotic paint repair system in which embodiments of the present invention are useful. The system 100 generally includes two units: a visual inspection system 110 and a defect repair system 120. Both systems can be controlled by motion controllers 112, 122, respectively, which can receive instructions from one or more application controllers 150. The application controllers can receive input from or provide output to a user interface 160. The repair unit 120 includes a force control unit 124 that can interface with an end effector 126. As shown in FIG. 1, the end effector 126 includes two tools 128, which in one embodiment can be arranged as further described in U.S. Provisional Patent Applications Nos. 62 / 940,950 and 62 / 940,960, both filed November 2, 2019. However, other arrangements are expressly contemplated. A visual inspection unit 110 can detect defects on the vehicle surface 130 , which can be repaired by a repair unit 120 .

[0019] The presence of a capable inspection system 110 is important for identifying and addressing defects to be repaired by the repair unit 120. The current state of the art in vehicle paint repair involves manually sanding / polishing defects using fine abrasives and / or polishing systems, with or without the assistance of power tools, all the way through while maintaining the desired finish (e.g., comparable to a mirror finish in a clear coat). Skilled personnel performing such repairs utilize extensive training and their senses to monitor the progress of the repair and make changes accordingly. Such advanced techniques are difficult to incorporate in robotic solutions, which have limited sensing capabilities.

[0020] Furthermore, while abrasive material removal is a pressure-driven process, many industrial manipulators typically operate natively in a position tracking / control regime and are optimized with positional accuracy in mind. This results in extremely rigid systems with very stiff error response curves (i.e., small misalignments result in very large corrective forces) that are inherently poor at force control (i.e., joint torques and / or orthogonal forces). Closed-loop force control techniques have been used (with limited utility) to address the latter, with more recent (and more successful) force-controlled flanges providing softer (i.e., less rigid) displacement curves that are much more suitable for sensitive force / pressure-driven processes.

[0021] Some repair processes use fluids to facilitate the abrasive removal process. For example, fluids can assist in swarf removal, reduce abrasive clogging, and improve uniformity of cut during use while extending the life of the abrasive article. For example, some sanding operations are wet sanding operations, which require dispersing water or another fluid onto the repair area before or during the sanding operation. In addition, polishing often requires that a polishing agent be dispensed before or during the polishing operation. After the repair is completed, water or another removal solvent may also be dispensed to remove debris.

[0022] Currently, the fluid required for an automated robotic system such as that shown in FIG. 1 includes a fluid source 170 coupled to a fluid line 180 that extends from the fluid source 170 to a dispenser (e.g., located at or near the tool 128). However, the longer the fluid line 180 must be, the greater the pressure differential required to transport the fluid from the source 170 to the dispense location. This may require a dedicated pump located near the source 170 or near the dispense point, or may require backpressure in the material reservoir. Additionally, because the robotic repair unit 120 has several degrees of freedom, as described below with respect to FIG. 2A , the line 180 also needs to be flexible to accommodate the various configurations required for the tool 128 to interact with defects at various points on the surface 130. Fluid may need to be dispensed to a first defect 192 and then to a second defect 194. The defects 192, 194 may be at different distances and heights from the fluid source 170, which may necessitate dynamic pressure control provided by pumps at the source 170 and / or dispensers. A solution that reduces the need for specialized machinery and provides a lower cost option for delivering fluid to the repair area on the work surface is desired.

[0023] Additionally, different portions of the repair process require different fluids. For example, wet sanding requires a water supply 170. A polishing operation may use a first polishing agent from a first polishing agent source 170 for the first polishing operation, followed by a second polishing agent requiring a second polishing agent source 170 for the second polishing operation. This necessitates several fluid sources 170, each with a fluid line 180, to avoid contamination or mixing of the dispensed fluids. Many of these fluids are used in relatively small quantities for a given repair operation, resulting in fluids remaining in the fluid lines 180 when not in use, potentially drying out, separating, or clogging. In addition to potentially delivering substandard dispensed fluid, this can cause damage to the lines 180 and any associated pumps, dispensers, or nozzles downstream of the sources 170. Currently, this risk is mitigated by running solvent through lines 180, dispensers and nozzles, and any pumping mechanisms to ensure there is nothing in the fluid path before connecting to new fluid source 170. However, this often requires the use of environmentally unfriendly solvents, resulting in waste of polishing agents or other fluids that are washed out of lines 180. A solution that reduces the need for dedicated fluid delivery machinery and reduces the potential for damage to robotic repair unit 120 or associated components, while providing a steady source of fluid needed for polishing operations, is desirable.

[0024] FIG. 2A is a schematic diagram of a paint repair robot that may be useful in embodiments of the present invention. The robot repair unit 200 has a base 210, which may be stationary in some embodiments. In other embodiments, the base 210 may move in either translation or rotation about the x-, y-, and / or z-axes. For example, the robot 200 may have a base 210 fixed to a rail system configured to move with the vehicle being repaired. Depending on the defect location, the robot 200 may need to move closer to or farther from the vehicle, or may need to move higher or lower relative to the vehicle. A mobile base 200 can make repairing hard-to-reach defects easier.

[0025] The robotic repair unit 200 has one or more tools 240 capable of interacting with the work surface. The tools 240 may, in one embodiment, include a back-up pad or another suitable abrasive tool. During the abrading operation, the tools 240 may have an abrasive disc or other suitable abrasive article attached using adhesive, hook and loop, clip systems, vacuum, or other suitable attachment systems. Because the tools 240 are mounted to the robotic repair unit 200, they have the ability to be positioned within the degrees of freedom provided by the robotic repair unit 200 (in most cases, six degrees of freedom), as well as within any other degrees of freedom with their reference coordinate system (e.g., compliant force control 230 unit).

[0026] 2A, the robotic repair unit 260 has several joints 260, each of which can be movable in the x and y directions. Additionally, in some embodiments where the joints 260 are ball joints, each of which can be movable in the z direction. The ability to move the robotic repair unit is important because it allows access to defects at different locations on the vehicle being repaired. However, difficulties exist when designing the supply of fluid from an external source.

[0027] The ability to reduce the distance fluids need to travel from their source to their dispensing location is desirable. Additionally, solutions that reduce the use of hazardous or environmentally unfriendly solvents are desirable. Additionally, solutions that lead to improved control over fluid dispensing are desirable. Embodiments provided herein provide a self-contained dispensing system that can be attached to a robotic repair unit and easily replaced without the need for hazardous solvents.

[0028] 2B shows several possible arrangements for mounting a self-contained fluid dispensing system. A dispenser may be positioned near the dispensing location 290. The dispenser may include a pneumatic gun that uses an air source (not shown) to atomize the incoming fluid stream and dispense the fluid stream through a nozzle. Many components of the self-contained system may be disposable or easily replaceable. For example, any of the fluid lines, fluid containers (or container liners), and nozzles may be easily replaceable. In some embodiments, the replaceable components are made from a plastic that is inert to the fluid being dispensed.

[0029] 2B, robotic repair unit 200 can have a self-contained fluid distribution system located in any suitable location. For example, fluid container 285 may be located on or downstream from the force controller so that fluid travels only through line 286 before reaching distribution location 290. This location allows for automatic detection of low fluid levels, for example, by sensing the current weight of container 285 approaching or reaching empty.

[0030] In another embodiment, fluid container 280 is located on the third arm portion such that the fluid travels through line portion 281 and line portion 286 before reaching dispensing location 290. Line 281 may need to be somewhat flexible, but by placing the fluid container at location 280, the vertical travel distance traveled by the fluid remains relatively constant.

[0031] In another embodiment, the fluid container may be located on the second arm portion at location 275. The presence of a junction between the second and third arm portions may require line portion 276 to have some flexibility or may require some built-in slack to accommodate the movement of robotic unit 200 during repair of defects on the vehicle surface.

[0032] In another embodiment, the fluid container 270 can be located on the first arm portion such that the fluid flows through the fluid line 272 to the dispensing location 290. This location may require additional pressure control to ensure that the fluid can be dispensed to the repair defect location where the dispensing location 290 is located lower than the fluid exit point from the fluid container 270.

[0033] As shown in FIG. 2B, as the fluid container is located further away from the dispensing location 290, the length of the fluid line required increases, as does the amount of pressure required to transport the fluid to the dispensing location 290.

[0034] 2B shows fluid containers 270, 275, 280, and 285 mounted directly to components of robotic repair unit 200. However, this is for purposes of understanding only. Fluid containers can also be mounted, for example, on components extending from the first, second, or third arm portions to utilize gravity to aid in fluid distribution.

[0035] 3 illustrates one embodiment of a self-contained fluid dispensing system. System 300 includes a dispenser 310 coupled to a fluid line 320, which is coupled to a fluid container 340. System 300 may also include a pump 330, which may be coupled to a motor (not shown) using port 332. The motor may be an air motor or a servo motor and may control the metering of fluid. Because pump 330 can volumetrically control the flow of fluid through line 320, the controlled metering can also serve as an indicator of when container 340 is nearing empty.

[0036] The dispenser 310 includes a nozzle 312 that dispenses atomized fluid in the direction indicated by arrow 314. The dispenser 310 may have one or more air intake ports 316 that couple to a pressurized air supply. However, in some embodiments, the dispenser 310 atomizes the fluid without an air source.

[0037] The fluid container 340, in some embodiments, is compressible. As shown in FIG. 3, the fluid container 340 is a compressible bag that can have an expanded configuration when full and a compressed configuration when empty. In some embodiments, an optical sensor can be used to detect when the container 340 is nearing empty. In some embodiments, the fluid container 340 is located in a more rigid mounting container that is attached to the robotic repair assembly either on an arm component, as described in FIG. 2B, or in another suitable location.

[0038] FIG. 4 illustrates another embodiment of a self-contained dispensing system 400. While a dispensing gun 410 having a trigger is shown in FIG. 4, a trigger such as that shown in FIG. 4 may or may not be present in an automated system. The dispensing gun 410 includes a pneumatic air intake 430 that can be coupled to a compressed air source to spray fluid through a nozzle 450. A fluid source 420 is directly coupled to the dispensing gun 410 by a coupler 440 that fits between the gun 410 and the nozzle 450. In the embodiment of FIG. 4, the coupler 440, the nozzle 450, and / or the fluid container 420 may be made from disposable materials. The coupler 440 may be designed to allow the coupler 440 to be easily separated from the dispensing gun 410 if a repair job requires a different fluid than the fluid present in the container 420.

[0039] 5 shows another embodiment of a self-contained dispensing system 500. A dispensing gun 520 is directly coupled to a fluid container 510 via a coupler 540. Air is supplied through line 550 and fluid is dispensed in an atomized spray through a nozzle 530. The fluid container 510 is a rigid container and may have a fluid liner contained within the fluid container so that the container 510 does not need to be replaced but can accept a new liner containing the fluid to be dispensed.

[0040] FIG. 6 shows another embodiment of a self-contained fluid dispensing system 600 including a fluid source 610 coupled to a dispenser 620 via a fluid line 630. The fluid line 630 couples to the dispenser 620 via a first coupler 640. The fluid source 610 couples to the fluid line 630 via a second coupler 650. In one embodiment, the fluid line 630 is flexible, allowing it to accommodate the movement of the arm components of the robotic repair unit during repair. Although not shown in FIG. 6, in some embodiments, the fluid container 610 is a fluid liner held in place by a rigid fluid container attached to the robotic repair unit.

[0041] FIG. 7 illustrates a pneumatic dispenser for an automated repair unit. However, while a pneumatic dispenser is described herein as one possible fluid dispenser, other configurations are possible, such as a fluid spray nozzle or a pressure pot that pressurizes material directly at the source. Pneumatic dispenser 700 includes an air inlet 702 and a fluid inlet 704. A fluid dispensing control 706 may allow for adjustment of the fan spray width, for example, by increasing or decreasing the applied fluid pressure. Pneumatic dispenser 700 may also include an air flow control 708 that allows for decreasing or increasing the air pressure. Dispenser 700 may include an attachment mechanism 710 that allows for attachment to a tool or end effector of a robotic repair unit. In some embodiments, the system may also include a fluid needle adjustment 712.

[0042] 8 illustrates a method for robotic defect repair, according to one embodiment of the present invention. Method 800 is an overview of how a robotic repair system repairs defects, according to at least some embodiments described herein.

[0043] In block 810, defects are detected and defect locations and characteristics are identified. Subsequently, commands related to the detected defects are received by the repair unit from a robotic controller, such as application controller 150 of FIG. 1. While not limited to the embodiments discussed herein, the defect areas can be detected by the image 802 of the surface or can be associated with locations on the vehicle 804 where defect characteristics are identified.

[0044] Blocks 820, 830, and 840 relate to repairing the detected defects. The defects may be repaired in one or more polishing operations. For example, the defective area may be first sanded and then polished. The defects may be inspected between the sanding and polishing steps, and depending on whether the defects were successfully repaired, the sanding and / or polishing steps may be repeated.

[0045] At block 820, a fluid is dispensed onto the repair area. The fluid may be, for example, water 812 for a wet sanding or wet polishing operation. The fluid may also be a polishing agent 814 for a polishing operation. The polishing agent 814 may actually refer to a variety of polishing agents useful for various operations. Different polishing agents 814 may have different viscosities and different abrasive properties. Depending on the repair operation, other fluids 816 may also be dispensed. The fluid may be dispensed using, for example, a self-contained fluid distribution system described in embodiments herein, or any other suitable self-contained fluid distribution system.

[0046] At block 830, the defect is polished. Polishing the defect may include a sanding operation 822, a denibbing operation 824, a polishing operation 826, or another operation 828. Polishing the defect includes contacting a tool with the defect area. Polishing may occur before, after, or simultaneously with the fluid dispensing of block 820.

[0047] At block 840, the fluid and / or waste material is removed from the work surface. Removing the fluid may also include removing waste material generated from the sanding operation, including clear coat or paint "swarf." Removing the fluid may be done manually during a human inspection operation, or may be done entirely automatically with a tool on the repair unit or by a separate robotic unit. Fluid removal may include physical wiping 832 with an absorbent article, or may include the use of a spraying operation 834, a vacuum operation 836, or another suitable operation 838.

[0048] 9 illustrates a method for replacing a self-contained fluid distribution system. The system may include, for example, components similar to those described with respect to FIGS. 4-6 or another suitable self-contained system. At least some systems contemplated herein are designed to dispense polishing agents, which may clump or solidify upon contact with carbon steel. For that reason, it is desirable for the polishing agent to be contained in a manner that allows it to be replaced without contacting the metal components of the robotic repair unit.

[0049] At block 910, the fluid is dispensed by the fluid system. A pump 902, which may have an associated motor 904, may be used to dispense the fluid. However, other fluid movement mechanisms are also contemplated, as shown in block 906. For example, if the viscosity of the fluid is low enough and the fluid container is positioned so that gravity provides sufficient pressure, the fluid system may not require a pump to dispense the fluid. Additionally, the fluid container may be coupled to a compressed air source, which may provide compressed air at a pressure sufficient to drive the fluid to the dispenser.

[0050] At block 920, it is detected that the fluid container is empty or nearing empty. Low fluid levels can be detected using parameter-based tracking as shown in block 912, such as volume, time, weight, optical, or contact switches. For example, a pump or motor system may be able to volumetrically track fluid leaving the fluid source. For example, in an embodiment where the fluid container is attached to the tool side of the force control, low fluid levels can also be detected using weight sensing unit 914. The force control can sense weight and accurately measure a change in weight corresponding to most (or all) of the fluid leaving the fluid container, or can detect that the current weight corresponds to a low fluid level. In another embodiment, low fluid levels can be detected with an optical sensor 916. For example, polishing agents may not be optically transparent. In one embodiment, such as that shown in FIG. 5, an optical sensor can detect the current fluid level and may be able to detect when the current fluid level drops to or below the replacement level. For example, in another embodiment as shown in Figures 3 and 4, an optical sensor can detect when a bag-type fluid container has reduced in volume or has compressed sufficiently to reach a low fluid level.

[0051] At block 930, the fluid source is replaced. A self-contained fluid dispensing system may include a dispenser, a fluid container, a fluid liner in the fluid container, lines connecting the container to the dispenser, and a nozzle. Replacing the fluid source may include replacing some or all of these components. To avoid the use of potentially carcinogenic or other harmful solvents, it may be preferable for components that interact with the fluid being dispensed to be replaced each time the fluid is changed. For example, a used fluid liner and used fluid line may be replaced with a new fluid liner and fluid liner filled with the fluid being dispensed. In some embodiments, the nozzle may also be replaceable. In embodiments in which the fluid is dispensed directly from a container, the used container is replaced with a new container. In some embodiments, as shown in FIG. 11, new components may be provided in a kit, and a new fluid-filled liner or fluid-filled container is filled with a predetermined amount of a given fluid.

[0052] As indicated in block 922, fluid replacement may require some manual intervention. For example, if a low or empty fluid level is detected, the robotic repair unit may indicate the need for replacement either visually, audibly, or via another suitable alarm. A human operator may then remove the used components and replace them with new components. In another embodiment, at least some portions of the replacement are automatic, as indicated in block 924. For example, the robotic repair unit or another robotic unit may retrieve the used components, dispose of the used components, retrieve new components, and / or install the new components.

[0053] At block 940, the replaced fluid source is detected. In some embodiments, the robotic repair unit may detect that the fluid source has been replaced. The replacement may be detected, for example, by an operator manually resetting a fluid counter, as shown in block 932. For example, in embodiments where the self-contained fluid dispensing system includes a servo motor capable of measuring the volume of dispensed fluid, the manual reset may include resetting the count to zero. In embodiments where weight sensing is possible, in which a fluid container is attached to a portion of the robotic repair unit, detecting the new fluid source unit may also include a weight sensor detecting that the tool-side weight corresponds to a full fluid container, as shown in block 934. Detecting the replaced fluid source unit may also include optical sensing, for example, an optical sensor detecting that a new fluid container has been reinstalled. In other embodiments, other suitable sensing systems may be possible.

[0054] At block 950, the type of fluid installed in the robotic repair unit is recorded. For example, in embodiments where the new component is part of a kit, the new fluid container or liner may include a barcode / QR code or other signifier of the contents. Depending on the parameters of the installed fluid, the controller may modify the repair trajectory or force profile of the abrasive tool. In embodiments where the new component includes signification, the fluid parameters may be automatically detected and communicated to the controller, as shown in block 944. However, it is also contemplated that manual recording may occur, as shown in block 942. It is important to note that with a robotic repair unit, lack of knowledge or control of the materials used in the process can also result in errors or malfunctions in the repair equipment, which can result in damage to the repair equipment or the vehicle being repaired.

[0055] The components of the self-contained fluid dispensing system, in some embodiments, are designed to be disposable to reduce the need for undesirable, hazardous, and environmentally corrosive chemicals. In some embodiments, the only component that is not replaced is the dispenser itself. All replaceable components, including liners, containers, fluid lines, and nozzles, may be made of plastic materials that are inexpensive enough to replace each time the fluid components are changed. In embodiments where the nozzle is one of the components that is replaced, replacement is essentially solvent-free.

[0056] 10 illustrates a robotic repair unit 1000 according to embodiments discussed herein. The robot 1000 may have a robotic movement mechanism 1008 that may enable the robot 1000 to move, for example, relative to the vehicle being repaired. The robot 1000 also includes a controller 1030 that may control the operation of the robot 1000 and its components based on either manual input or input received from sensors 1002. The robot 1000 may also include sensors specific to the self-contained fluid distribution system 1020, such as a fluid level detector 1004 and a fluid exchange detector 1006. However, these sensors may be mounted separately from the robot 1000, on the robot arm 1010, or as part of the self-contained fluid distribution assembly 1020.

[0057] The robotic repair unit 1000 includes a robotic arm 1010. The robotic arm 1010 includes one or more tools on an end effector (not shown) attached to a force control 1012. In embodiments where compressed air is required to drive fluid through fluid lines 1028 to a dispenser 1026, the robotic arm 1010 may also be attached to an air line 1014. The robotic arm 1010 may have its own movement mechanism 1016 to facilitate positioning of the arm components and the tool (not shown) relative to the surface being repaired.

[0058] The self-contained fluid distribution system is mounted on the robotic arm 1010. As mentioned above, the self-contained fluid distribution system may be mounted on any suitable arm component of the robotic arm 1010. However, it may be beneficial to mount the fluid source 1022 on the tool side of the force control 1012 to utilize weight sensing. However, other arrangements are also expressly contemplated. The self-contained fluid distribution system includes components that are intended to be disposed of after a single use to reduce the use of harmful solvents in the repair area. A fluid line 1028 transports fluid from the fluid source 1022 to the fluid dispenser 1026. Depending on the viscosity of the fluid being dispensed and the relative placement of the fluid source to the dispenser 1026, a pump 1024 may be required to facilitate fluid flow. In some embodiments, an air line 1014 is provided to the fluid source 1022 to provide an additional source of pressure for the dispensed fluid to promote uniform flow.

[0059] When the fluid source 1022 is empty or reaches a low enough level to indicate replacement, the replacement component is removed from the replacement component source 1040. Replacement of the fluid line 1028, fluid source 1022, and / or pump 1024 can be done manually, semi-automatically, or automatically.

[0060] FIG. 11 illustrates a replacement kit for a self-contained fluid dispensing system. The replacement kit 1100 includes a fluid container 1110 containing a fluid 1112. The fluid may be water, polish, wax, or another fluid for vehicle refinishing work. The fluid container 1110 is a single-use container intended to be replaced after the fluid 1112 has been used. The fluid container 1110 may include an opening 1113 that can be coupled to a compressed air source, which provides additional pressure for dispensing the fluid 1112. However, in embodiments where the fluid 1112 has a viscosity low enough to flow on its own, or in embodiments where a pump 1130 is present to facilitate fluid flow, the opening 1113 may not be necessary.

[0061] The replacement kit 1100 may also include a connection 1116 for coupling the fluid container 1110 directly to a dispenser or directly to a fluid line 1114. In some embodiments, the replacement kit 1100 also includes a nozzle 1120. The connection 1116 may directly couple the fluid container 1110 to the nozzle 1120 such that the fluid line 1114 is not required.

[0062] In some embodiments, the fluid container 1110 may be a liner coupled to the fluid line 1114 via a separate container that does not need to be replaced every time the fluid needs to be replenished.

[0063] A fluid dispensing system for a robotic repair unit is presented, the system including a fluid container, a fluid dispenser associated with the robotic repair unit, a fluid coupler connecting the fluid container to the dispenser, and a mounting mechanism configured to couple the fluid container to the robotic repair unit.

[0064] The fluid distribution system may be implemented such that the fluid distribution system is self-contained on the robotic repair unit.

[0065] The fluid distribution system may be implemented to include a pump.

[0066] The fluid distribution system may be implemented to include a motor.

[0067] The fluid distribution system may be implemented to include an air source.

[0068] The fluid dispensing system may be implemented such that the dispenser is a pneumatic dispenser.

[0069] The fluid dispensing system may be implemented such that the fluid container and the fluid coupler are disposable.

[0070] The fluid distribution system may be implemented such that the fluid container and the fluid coupler comprise plastic.

[0071] The fluid distribution system may be implemented such that the fluid container is a disposable liner.

[0072] The fluid distribution system may be implemented such that the fluid liner is a compressible liner that compresses in volume as fluid is dispensed.

[0073] The fluid dispensing system may be implemented such that it is mounted such that gravity provides a portion of the pressure required for fluid to flow from the fluid container to the fluid dispenser.

[0074] The fluid dispensing system may be implemented such that it is mounted such that gravity provides all of the pressure necessary for fluid to flow from the fluid container to the fluid dispenser.

[0075] The fluid delivery system may be implemented such that the pump is disposable.

[0076] The fluid dispensing system may be implemented such that the fluid container includes a port configured to receive a source of compressed air.

[0077] The fluid dispensing system may be implemented such that the fluid dispensing system includes a disposable nozzle that couples to a fluid dispenser.

[0078] The fluid dispensing system may be implemented such that the fluid container and the fluid coupler are single-use components.

[0079] The fluid distribution system may be implemented such that the fluid container and the fluid coupler comprise plastic.

[0080] The fluid dispensing system may be implemented such that the fluid container includes indicia that identify the fluid within the fluid container.

[0081] The fluid distribution system may be implemented such that the fluid distribution system is a solvent-free system.

[0082] The fluid dispensing system may be implemented such that the fluid coupler includes a connector that directly connects the fluid container to the dispenser.

[0083] The fluid distribution system may be implemented such that the fluid coupler includes a fluid line.

[0084] The fluid distribution system may be implemented such that the fluid lines are flexible.

[0085] The fluid distribution system may be implemented such that the fluid container is configured to be attached to the tool side of the force control.

[0086] The fluid dispensing system may be implemented to include a sensor for detecting low fluid levels. The sensor may be a weight sensor, an optical sensor, or a volume sensor.

[0087] A method for supplying fluid for a repair operation is presented, comprising: positioning a dispenser proximate to a repair area; and automatically dispensing fluid from the dispenser to the repair area. The dispenser receives fluid from a self-contained fluid dispensing system mounted on a robotic repair unit. The self-contained fluid dispensing system includes a fluid container coupled to the dispenser.

[0088] The method may be implemented such that the fluid container includes a disposable liner that contains the fluid.

[0089] The method may be implemented such that the fluid container includes an air port for receiving compressed air.

[0090] The method may also be implemented to include metering the dispensed fluid.

[0091] The method may be implemented such that the disposable liner is a bag-type liner that compresses as fluid is dispensed.

[0092] The method may be implemented such that the disposable liner is plastic.

[0093] The method may be implemented such that the fluid container is coupled to the dispenser using a coupler. The fluid container is a single-use container.

[0094] The method may be implemented such that the coupler is a fluid line, the fluid line being a single use fluid line.

[0095] The method may be implemented such that the coupler is a single-use coupler.

[0096] The method may be implemented such that a dispenser is coupled to the nozzle.

[0097] The method may be implemented such that the nozzle is a single-use nozzle.

[0098] The method may be implemented such that the self-contained fluid distribution system is configured to be replaced without a solvent.

[0099] The method may also be implemented to include removing fluid from the repair area.

[0100] The method may be implemented such that the repair area includes the defect.

[0101] The method may be implemented such that the defect is on a vehicle.

[0102] The method may be implemented such that the vehicle and robotic repair unit are moving during the step of automatically dispensing the fluid to the repair area.

[0103] The method may be implemented such that automatically dispensing fluid includes dispensing a continuous flow of fluid.

[0104] The method may be implemented such that automatically dispensing fluid includes dispensing a metered amount of fluid.

[0105] The method may be implemented such that the measured quantity is controlled by a controller associated with the robotic repair unit.

[0106] The method may be implemented such that the fluid is water or a polishing agent.

[0107] A method for replacing a fluid source on a robotic repair system is presented. The method includes detecting a replacement fluid level in a used fluid source using a first sensor. The method also includes removing the used fluid source. The method also includes installing a new fluid source. The method also includes detecting the new fluid source using a second sensor.

[0108] The method may be implemented such that installing the new fluid source includes installing the new fluid source in a container attached to the robotic repair system.

[0109] The method may be implemented such that installing the new fluid source includes connecting the new fluid source to a fluid dispenser mounted on the robotic repair system.

[0110] The method may be implemented such that a new fluid source is connected to the fluid dispenser via a fluid line.

[0111] The method may be implemented such that the fluid line is a flexible fluid line.

[0112] The method may be implemented such that the flexible fluid line and new fluid source contain single-use materials.

[0113] The method may be implemented such that the fluid dispenser is attached to a robotic repair system.

[0114] The method may be implemented such that a new fluid source is attached to the tool side of the robotic repair system.

[0115] The method may be implemented such that the first sensor is a weight sensor that detects the weight of the used fluid source, which is indicative of the replacement fluid level.

[0116] The method may be implemented such that the replacement fluid level is empty.

[0117] The method may be implemented such that the replacement fluid level is a low fluid level.

[0118] The method may be implemented such that the first sensor or the second sensor is selected from a weight sensor, a volume sensor, or an optical sensor, respectively.

[0119] The method may be implemented to further include detecting a fluid type in the new fluid source and providing the detected fluid type to a controller associated with the robotic repair unit.

[0120] The method may be implemented such that removing the used fluid source includes removing a disposable component of the self-contained fluid dispensing system.

[0121] The method may be implemented such that the self-contained fluid dispensing system includes a fluid line coupling the used fluid container to the dispenser.

[0122] The method may be implemented such that the self-contained fluid distribution system includes a pump that facilitates dispensing fluid through the fluid line.

[0123] The method may be implemented such that the spent fluid container is a spent fluid liner.

[0124] A robotic repair unit is presented that includes a robotic arm having a force control coupled to an end effector including an abrasive tool, and a self-contained fluid dispensing system configured to dispense fluid onto a work surface, the self-contained fluid dispensing system including a fluid dispenser and a fluid container coupled to the fluid dispenser, the fluid container being mounted to the robotic repair unit.

[0125] The method may be implemented such that the exchange of the fluid container does not involve a solvent.

[0126] The method may be implemented such that the fluid dispenser is a pneumatic fluid dispenser.

[0127] The method may be implemented such that the fluid container includes a fluid liner configured to contain the fluid to be dispensed.

[0128] The method may be implemented such that the fluid container includes an air port configured to couple to a source of compressed air.

[0129] The method may be implemented to further include a fluid line coupling the fluid liner to the fluid dispenser.

[0130] The method may be implemented such that the fluid liner and fluid line are single-use items.

[0131] The method may also be implemented to include a single-use pump.

[0132] The method may be implemented such that replacement of single-use fluid liners and single-use fluid lines does not involve solvent agents.

[0133] The method may be implemented such that the dispenser includes a disposable nozzle.

[0134] The method may be implemented such that the fluid container is attached to the tool side of the force control unit of the robotic arm.

[0135] The method may be implemented such that the force control detects a change in weight of the fluid container corresponding to a low fluid level.

[0136] The method may be implemented such that the fluid is water or a polishing agent.

[0137] The method may be implemented to further include a detector configured to identify the type of fluid in the fluid container.

[0138] The method may be implemented such that the detector is configured to identify the fluid type based on indicia on the fluid container.

[0139] Throughout this specification, references to "one embodiment," "a particular embodiment," "one or more embodiments," or "an embodiment," regardless of whether the term "exemplary" is included before the term "embodiment," mean that the particular feature, structure, material, or characteristic described in connection with that embodiment is included in at least one of the particular exemplary embodiments of the present disclosure. Thus, the appearances of phrases such as "in one or more embodiments," "a particular embodiment," "in one embodiment," or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same particular exemplary embodiments of the present disclosure. Furthermore, particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

Claims

1. A robot system for performing polishing work, comprising: A driving robot arm; a force control unit coupled to the driving robot arm; an end effector coupled to the force control, the end effector configured to move relative to the force control; an abrasive tool coupled to the end effector, the abrasive tool configured to contact a work surface and remove material when the end effector is aligned with the force control; and a fluid distribution system; the fluid distribution system comprising: a fluid container; a fluid dispenser configured to dispense fluid onto the work surface; a fluid coupler connecting the fluid container to the fluid dispenser; Equipped with The robotic system, wherein the fluid dispenser is mounted to a robotic repair unit.

2. The robot system of claim 1, wherein the fluid distribution system is self-contained on the drive robot arm.

3. A robot system as described in claim 1 or 2, further comprising a pump.

4. A robot system described in any one of claims 1 to 3, wherein the fluid container and the fluid coupler are disposable.

5. The robot system of claim 4, wherein the fluid container is a liner, and the liner is disposable.

6. The robotic system of claim 5, wherein the fluid distribution system is mounted so that gravity provides a portion of the pressure required for fluid to flow from the fluid container to the fluid dispenser.

7. The robotic system of claim 6, wherein the fluid distribution system is mounted so that gravity provides all of the pressure required for fluid to flow from the fluid container to the fluid dispenser.

8. A robotic system as described in any one of claims 1 to 7, wherein the fluid container has a port configured to receive a source of compressed air.

9. A robotic system as described in any one of claims 1 to 8, wherein the fluid distribution system comprises a disposable nozzle coupled to the fluid dispenser.

10. A robotic system as described in any one of claims 1 to 9, further comprising a sensor for detecting low fluid levels, the sensor comprising a weight sensor, an optical sensor, or a volume sensor.

11. The end effector is a first end effector, The robot system according to any one of claims 1 to 10, further comprising a second end effector to which a second polishing tool is coupled.

12. A robot system as described in any one of claims 1 to 10, wherein the end effector is configured to be rotatable so as to be aligned with the force control unit.

13. A robotic repair unit comprising: a robotic arm including a force control, an end effector coupled to the force control and configured to move relative to the force control, and an abrasive tool coupled to the end effector; a freestanding fluid distribution system configured to distribute fluid to a work surface; The self-contained fluid distribution system comprises: a fluid dispenser attached to the robotic arm and positioned adjacent the polishing tool; a fluid container coupled to the fluid dispenser; A robotic repair unit having:

14. A robotic repair unit as described in claim 13, wherein the fluid container comprises a fluid liner configured to contain the fluid to be dispensed.

15. A robotic repair unit as described in claim 13 or 14, wherein the fluid dispenser is provided with a disposable nozzle.

16. A robot repair unit described in any one of claims 13 to 15, wherein the fluid container is attached to the tool side of the force control unit of the robot arm.

17. A robotic repair unit as described in any one of claims 13 to 16, wherein the force control unit is configured to detect a change in weight of the fluid container corresponding to a low fluid level.

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