Actuated Print Head Assembly for Contoured Surface Coating

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Solution Overview

Problem

The existing methods for treating and coating large, contoured surfaces on machines such as aircraft are time-consuming and resource-intensive, requiring serial masking and painting operations that are inefficient for complex geometries.

Innovation Solution

An automated surface treatment system comprising an adjustable base with applicator assemblies that include sensors for scanning the surface and actuators for maintaining orientation, allowing for precise application of surface treatments across varying radii and geometries, facilitated by a control system for real-time adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If serial masking and painting operations are used for coating large contoured surfaces, then decorative livery can be applied, but the process requires significant time and resources

Engineering Contradiction:

Improvecoating precisionVSAvoidcoating speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The coating system is divided into multiple independently controllable applicator heads, each equipped with its own actuator and sensor. This segmentation allows parallel processing of different surface sections, dramatically improving productivity while maintaining precision through individual control of each applicator head

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary scanning of the contoured surface to create a digital model before coating begins. This preliminary action enables pre-calculation of applicator head positions and orientations, allowing the coating process to proceed efficiently without real-time adjustments, thus improving both speed and precision

Inventive Principle:

Principle #10Preliminary action

2Productivity

If multiple applicator heads are used to increase coating speed, then productivity improves, but maintaining uniform orientation on contoured surfaces becomes more complex

Engineering Contradiction:

Improvecoating speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Each applicator head is designed as a universal module that can adapt to any contoured surface geometry. The combination of gimbal mechanisms, adjustable radii arms, and active orientation control creates a multi-functional applicator that maintains uniform coating orientation across diverse surface shapes, managing complexity through standardization

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system incorporates sensors on each applicator head that continuously monitor position, orientation, and surface geometry. This feedback is fed to the control system, which automatically adjusts actuator positions to maintain uniform coating application, reducing the practical complexity despite having multiple applicators

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If the applicator assembly maintains fixed orientation relative to the surface, then coating quality is improved, but the system cannot adapt to varying surface geometries

Engineering Contradiction:

Improvecoating uniformityVSAvoidsurface geometry adaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The applicator assembly employs dynamic orientation control through gimbal mechanisms and adjustable radii arms that allow real-time adaptation to varying surface geometries. The system dynamically calculates and adjusts the position and angle of each applicator head to maintain perpendicular orientation to the local surface, ensuring coating uniformity across complex 3D shapes

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system replaces purely mechanical positioning with a hybrid approach combining mechanical gimbals and radii arms with computer-controlled actuators and sensors. This substitution enables precise maintenance of applicator orientation relative to the surface normal, adapting to any geometry through electronic control rather than fixed mechanical constraints

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This system enables efficient and uniform application of surface treatments on complex surfaces, reducing time and resource requirements while ensuring proper alignment and coverage, even on irregularly shaped surfaces.

Implementation Method 1

The applicator actuator comprises a gimbal configured to pivotally support a base of the attachment frame, and to rotate the attachment frame about an axis of each applicator assembly

Methodology Applied

Scientific EffectGimbal: Gimbal

Data Source

PatentEP3321088B1Actuated print head assembly for a contoured surface

Publication Date: 2024.05.15 THE BOEING CO

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AI summary

An applicator assembly for treating a contoured surface including an attachment frame configured to secure and position an applicator head. The applicator head can be configured to apply a surface treatment to the contoured surface. The applicator assembly further includes, at least one sensor operatively coupled to the attachment frame and configured to scan the contoured surface and produce a contoured data set. Additionally, the applicator assembly includes an applicator actuator operatively coupled to the attachment frame and configured to manipulate the attachment frame such that the applicator assembly maintains an orientation of the applicator assembly relative to the contoured surface.