Method and system for painting an object

Abstract

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

Description

Technical Field

[0005]

[0001] (Cross - Reference to Related Applications) This application claims priority and all benefits to U.S. Provisional Application No. 63 / 265,939, filed Dec. 23, 2021, the content of which is hereby incorporated by reference in its entirety.

[0002] (Technical Field) This technical field generally relates to coatings, and more particularly to methods and systems for painting an object using an applicator (e.g., a spray gun or other applicator) operably coupled to a robot.

Background Art

[0003] A paint booth is a structure that provides an environment where ventilation, air filtration, and temperature control are carried out to enable painting of an object. Painting operations involve dispensing paint components such as solvents and particulate matter that must not enter the atmosphere in large quantities. Therefore, a paint booth is necessary to safely conduct such activities. For this reason, the environment inside the paint booth is enclosed and requires a high level of management and expertise. Trained and experienced personnel are often difficult to find and secure, and special personal protective equipment (PPE) is required to work in such dangerous enclosed spaces.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Therefore, it is desirable to provide a method and system for painting an object that addresses one or more of the aforementioned problems. Further, other desirable features and characteristics of the present disclosure will become apparent from the following detailed description and the appended claims, considered in conjunction with this background art.

Means for Solving the Problems

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

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

[0007] Various embodiments are described below, along with the following drawings where the same numbers indicate the same elements. [Brief explanation of the drawing]

[0008] [Figure 1] This is a block diagram of a method for robotically painting an object according to an exemplary embodiment.

[0009] [Figure 2] This is a perspective view of an applicator configured as a printhead according to an exemplary embodiment. [Modes for carrying out the invention]

[0010] The following detailed description is merely illustrative and not intended to limit the various embodiments or their applications and uses. Furthermore, it is not bound by the background art described above or the theories presented in the following detailed description.

[0011] As used herein, the term “on top of” means that the on top material can be in physical contact with the underlying substrate or layer, or that the on top material can be physically separated from the underlying substrate or layer by an intervening layer such as a clear coat on top, which can separate the on top material from the underlying substrate or layer (e.g., a primer layer) by a base coat. Since it is understood that components or objects can rotate or move, references to a component, object, or article (layer) on top of another component, object, or article (layer) refer to a particular orientation, with the understanding that the actual component, object, or article (layer) can rotate in different orientations.

[0012] The various embodiments contemplated herein relate to methods and systems for robotically painting objects. Referring to Figure 1, a method 100 for robotically painting an object is provided according to an exemplary embodiment. The object may be a component such as a part, for example a vehicle body or trim panel (e.g., exterior or interior body or trim panel) that can stand on its own, be mounted on a fixture, or be mounted on a vehicle, or an assembly of vehicle components, a part thereof, or the like.

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

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

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

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

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

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

[0019] In exemplary embodiments, the 3D scanner is positioned on a robot, for example, on the robot's base, or alternatively, on the robot's arm. The robot can be located inside or outside a paint booth. For example, the robot may be a floor-standing robot positioned inside the paint booth and mounted to the floor in a fixed position. Alternatively, the robot may be a mobile robot configured to enter and exit the paint booth as needed. In one embodiment, the 3D scanner is positioned on the arm of a robot mounted to the floor inside the paint booth, and the robot communicates with at least one processor to control the movement of the arm, thereby controlling the 3D scanner to scan an object. In another example, the 3D scanner is positioned on the base of a mobile robot, and the robot communicates with at least one processor to control the movement of the robot, thereby controlling the 3D scanner to scan an object. Alternatively, the 3D scanner may be mounted on the arm of a mobile robot, and the robot communicates with at least one processor to control the movement of the arm, thereby controlling the 3D scanner to scan an object.

[0020] Alternatively, the 3D scanner is positioned on a rail gantry system. The rail gantry system can be located inside or outside the paint booth. The 3D scanner is operably coupled to the rail gantry system, for example, and is movably positioned on the rail gantry system, and the rail gantry system communicates with at least one processor to control the movement of the rail gantry system and the resulting 3D scanner scanning objects. In another alternative embodiment, the 3D scanner is transported by a drone. The drone is mobile inside and optionally outside the paint booth. The 3D scanner is operably coupled to the drone, for example, and is transported by the drone, and the drone communicates with at least one processor to control the movement (e.g., flight, landing, and / or other) of the drone and the resulting 3D scanner scanning objects.

[0021] In an exemplary embodiment, the 3D scanner detects an object (STEP 106) or otherwise locates an object while communicating with at least one processor. For example, the object may be moved to a general area within the paint booth. Alternatively, the object may be outside the paint booth, in a general area near the paint booth. Whether the 3D scanner is positioned in a robot or a rail gantry system, it scans the general area containing the object and transmits the scan data to at least one processor, which uses the scan data to locate the object in the general area, including its position and / or orientation.

[0022] As described above, at least one processor instructs a 3D scanner to scan and collect surface data of an object, and this surface data is communicated to at least one processor for determining the surface and / or 3D shape of the object and / or for identifying the object. Furthermore, the 3D scanner and at least one processor work together to determine the area of ​​the object to be painted (STEP 108). For example, at least one processor can be operated to run an algorithm that instructs at least one processor to evaluate the data and determine the 3D shape of the object. At least one processor can use the algorithm to evaluate the surface data and / or 3D shape and identify areas or portions of the object's surface that require paint repair and / or refinishing or otherwise need it.

[0023] In an exemplary embodiment, an identifier is applied (e.g., manually or otherwise) to an area of an object to be painted (e.g., partially or fully surrounding an area that requires paint repair and / or refinishing). Non-limiting examples of identifiers include non-contact sensing devices such as radio frequency identification (RFID) tape, colored tape, RFID tags, ultra-wideband (UWB) devices, color contrast borders, and / or polygonal borders including corners or other tape or border masking materials that can be readily identified by a 3D scanner communicating with at least one processor. In an exemplary embodiment, an object including an identifier is scanned with a 3D scanner, and at least one processor uses the position data of the identifier to determine the area to be painted. For example, at least one processor can recognize a polygonal RFID tape border and determine that the area located inside the RFID tape border is the area to be painted.

[0024] Alternatively or additionally, at least one processor can communicate with and access a database that includes, for example, a plurality of corresponding 3D shapes, areas and / or portions of the surfaces of various parts / objects that require painting or additional painting, such as unfinished or at least partially unpainted parts / objects. In an exemplary embodiment, at least one processor matches the surface data and / or 3D shape to a specific part / object in the database that includes the corresponding area to be painted (e.g., matches the surface data / 3D shape to the corresponding 3D shape of a specific part / object). Further, in an exemplary embodiment, at least one processor uses an algorithm and / or the database to determine a specific paint formulation including color and any special effects, and the parameters (e.g., speed, index, offset distance, air pressure, number of coats, flash time, droplet generation frequency, and / or others, including process parameters or process specifications) used to paint an area of the object.

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

[0026] In an exemplary embodiment, with both the object and the robot disposed within the paint booth, method 100 proceeds to step (STEP110) of holding an applicator offset from the area of the object with a robot (e.g., the end of the robot's arm) in communication with at least one processor. In an exemplary embodiment, for example, in a refinish paint setting / coating or alternatively in an industrial paint setting / coating, the applicator is a spray gun. In another exemplary embodiment, the applicator is a print head, for example, in a refinish paint setting or alternatively in an industrial paint setting. In another exemplary embodiment, the applicator is a rotating bell applicator, for example, in an industrial paint setting.

[0027] Referring to Figure 2, if the applicator is a print head, the applicator may include one or more high-transfer-efficiency applicators for ejecting the coating composition. The coating composition 10 is ejected from one or more nozzles in a manner designed / controlled to form a fine stream, which may or may not break down into droplets. The fluid stream is targeted to the substrate 12 so that the jet or droplet reaches a specific location to form a continuous film or pattern on the substrate 12. As a result, there is essentially no overspray (droplets missing the target) and nearly 100% transfer efficiency (essentially all the paint going to the target location). In exemplary embodiments, the transfer efficiency of the coating composition deposited on the substrate 12 is 99.9% or higher. Some tolerance should be given for starting and stopping the high-transfer-efficiency applicator 16. This type of device has been called drop-on-demand, stream-on-demand, overspray-free, or ultra-high-transfer-efficiency applicator. The high-transfer-efficiency applicator 16 is distinguished from spray atomization techniques in which energy such as pneumatic, hydraulic, or centrifugal energy is introduced to partially control droplet size, trajectory, and velocity, creating a random distribution. Subsequently, some additional mechanism (electrostatic and / or shaping air) can guide the droplets of the coating composition 10 onto the substrate 12. In the case of paint sprays, there is always some overspray and loss of transfer efficiency.

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

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

[0030] In an exemplary embodiment, Method 100 proceeds to step (STEP 112) of moving an applicator over an area of ​​an object with a robot communicating with at least one processor (for example, by moving the robot's arm) while depositing paint from the applicator onto the area of ​​the object (for example, via spray (e.g., atomization) or stream, etc.). In an exemplary embodiment, the applicator is moved over the surface of an area of ​​an object along a path or pattern (e.g., a robot path, a spray path, a stream path, or similar) to provide complete coverage of the area with a desired coating thickness of paint.

[0031] In an exemplary embodiment, the applicator is a first applicator, the paint source is a first paint source, and the paint is a first coating. Method 100 includes the step of moving the first applicator relative to an area of ​​an object using a robot communicating with at least one processor, while depositing the first coating onto an area of ​​an object from the first applicator. Method 100 optionally proceeds to the steps of allowing the first coating to flush after it has been deposited onto the area of ​​the object, and releasing the first applicator from the robot. A second applicator is held offset from the area of ​​the object by a robot communicating with at least one processor. The second applicator is in fluid communication with a second paint source containing a second coating. The second applicator is moved relative to an area of ​​an object by a robot communicating with at least one processor, while depositing the second coating onto an area of ​​the object on top of the first coating from the second applicator.

[0032] In an exemplary embodiment, method 100 optionally proceeds to the steps of allowing a second coating to be flashed after it has been deposited on an area of ​​an object, and releasing the second applicator from the robot. The third applicator is held offset from the area of ​​the object by a robot communicating with at least one processor. The third applicator is in fluid communication with a third paint source containing the third coating. The third applicator is moved relative to the area of ​​the object by the robot communicating with at least one processor while depositing the third coating from the third applicator onto the area of ​​the object above the base coat. In an exemplary embodiment, the third coating is optionally flashed and the first, second, and third coatings are cured. In an exemplary embodiment, multiple layers of the first coating, the second coating, and the third coating independently can be deposited. Furthermore, in exemplary embodiments, the first coating, the second coating, and the third coating are independently selected from the group consisting of primers, sealers, base coats, clear coats, top coats, and / or tint coats.

[0033] While at least one exemplary embodiment is presented in the preceding detailed description of this disclosure, it should be understood that a vast number of variations exist. Furthermore, it should be understood that the exemplary embodiments are merely illustrative and are not intended to limit in any way the scope, applicability, or configuration of this disclosure. Rather, the preceding detailed description provides a convenient roadmap for carrying out the exemplary embodiments of this disclosure. It should be understood that various modifications can be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope of this disclosure as defined in the appended claims. [Explanation of Symbols]

[0034] 10 Coating composition 12 circuit boards 14 Coating layer 16 High Transfer Efficiency Applicators 22 Printhead Assembly 24 Coating layer thickness 28 Coating layer surface

Claims

1. A method for robotically painting an object, Steps include providing a paint booth, The step of providing a scanner robot mechanism comprising: a robot which is a mobile robot configured to enter and exit the paint booth; a 3D scanner disposed on the robot; and at least one processor which communicates with the 3D scanner and the robot; The steps include communicating with at least one processor to detect an object with the 3D scanner, A step of communicating with at least one processor and using the 3D scanner to determine the area of ​​the object to be painted, A step of holding an applicator by communicating with at least one processor and shifting the position of the object relative to the area using the robot, wherein the applicator is in fluid communication with a paint supply source containing paint, The steps include: depositing the paint from the applicator onto the area of ​​the object, communicating with at least one processor, and moving the applicator onto the area of ​​the object using the robot; Before holding and moving the applicator, the step of moving the object to the paint booth, Before holding and moving the applicator, the steps include moving the movable robot to the paint booth to deposit the paint on the area of ​​the object, Includes, A method wherein the step of holding and moving the applicator includes the step of holding and moving the applicator while the robot is positioned in the paint booth to deposit the paint onto the area of ​​the object.

2. The method according to claim 1, wherein (i) the applicator is a spray gun or a print head, (ii) the 3D scanner is a contact scanner, a non-contact scanner, or a combination thereof, or (iii) any combination of (i) to (iii).

3. The method according to claim 1, wherein the 3D scanner is a non-contact scanner, and the non-contact scanner is any of the following: an ultra-wideband (UWB) scanner, a camera scanner, a time-of-flight (TOF) camera, an acoustic scanner, a laser scanner, and a light-detection and ranging laser (LiDAR) scanner.

4. The method according to claim 1, wherein the step of detecting the object includes the step of scanning the object using the 3D scanner to generate data, and the step of determining an area of ​​the object to be painted includes the step of the at least one processor using the data to determine the 3D shape of the object.

5. (i) The at least one processor is operable to execute an algorithm that instructs the at least one processor to evaluate the data and determine the 3D shape of the object, (ii) The at least one processor communicates with a database containing a plurality of parts, each including a plurality of corresponding 3D shapes, and the at least one processor searches the database to match the data to one of the plurality of parts and to identify the corresponding 3D shape. (iii) The 3D scanner generates a point cloud as data corresponding to the 3D shape. or (iv) Any combination of (i) to (iii) above, The method according to claim 4.

6. The method according to claim 4, further comprising the step of applying an identifier for the area of ​​the object to be painted, the step of detecting the object comprising scanning the object including the identifier with the 3D scanner, the step of determining the area comprising determining the area to be painted by the at least one processor using the identifier, the identifier comprising a non-contact sensing device selected from radio frequency identification (RFID) tape, colored tape, RFID tag, ultra-wideband (UWB) device, or a combination thereof.

7. The applicator is a first applicator, the paint supply source is a first paint supply source, the paint is a first coating, and the step of moving the applicator includes the step of moving the robot with respect to the area of ​​the object, while depositing the first coating from the first applicator onto the area of ​​the object, The method described above is The steps include releasing the first applicator from the robot, A step of holding a second applicator by shifting its position relative to the area of ​​the object using a robot that communicates with at least one processor, wherein the second applicator is in fluid communication with a second paint supply source including a second coating, The steps of moving the second applicator over the area of ​​the object, using the robot which is communicating with the at least one processor, while depositing the second coating from the second applicator onto the area of ​​the object which is on the first coating, The method according to claim 1, further comprising:

8. The steps include releasing the second applicator from the robot, A step of holding a third applicator by shifting its position relative to the area of ​​the object using the robot which communicates with at least one processor, wherein the third applicator is in fluid communication with a third paint supply source including a third coating, The steps of moving the third applicator to the area of ​​the object using a robot that is communicating with at least one processor, while depositing the third coating from the third applicator onto the area of ​​the object that is on the second coating, The method according to claim 7, further comprising:

9. A system for robotically painting objects, equipped with a scanner robot mechanism, The scanner robot mechanism, Paint booth and A robot which is a mobile robot configured to enter and exit the aforementioned paint booth, A 3D scanner configured to scan the aforementioned object and positioned on the robot, The 3D scanner and the robot communicate with at least one processor, wherein the 3D scanner communicating with the at least one processor is configured to cooperate in detecting the object and determining the area of ​​the object to be painted. An applicator configured to be in fluid communication with a paint supply source containing paint, wherein the robot communicating with at least one processor is configured to cooperate in moving the applicator relative to the area of ​​the object, while offsetting the applicator relative to the area of ​​the object and depositing the paint from the applicator onto the area of ​​the object, A system equipped with these features.

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