Adaptive Robot Coating Paths for Variable Surface Geometry
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Solution Overview
Problem
Existing methods struggle to generate robot path data for coating spatial substrates with high geometric variation, leading to inconsistent coating application and quality, especially in automotive refinishing where CAD data is not available.
Innovation Solution
A computer-implemented method generates robot path data using spatial substrate data, coating material data, and rule sets for edges and surfaces, allowing automated coating on substrates with high geometric variation, incorporating a scanning device to determine geometry and color before coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual coating application is used, then flexibility to handle geometric variation is improved, but coating consistency and quality deteriorate
Solution Approach 1:
The system uses self-service by having the robot scan and automatically generate its own path data without manual programming. The robot independently acquires spatial substrate data, processes it through the path data generation system, and executes the coating process, eliminating the need for manual intervention while maintaining consistency across varying geometries.
Solution Approach 2:
The system dynamically adjusts coating parameters based on the scanned spatial substrate data. The path data generation system modifies coating parameters such as spray distance, angle, and speed according to the actual geometry detected, enabling consistent coating quality across substrates with high geometric variation.
2Manufacturing precision
If automated coating with pre-defined paths is used, then coating consistency is improved, but adaptability to geometric variation deteriorates
Solution Approach 1:
The system transitions from static pre-defined paths to dynamic adaptive paths. The robot performs real-time scanning of the spatial substrate and dynamically generates coating paths based on the detected geometry. This dynamic approach allows the automated system to adapt to geometric variations while maintaining coating consistency through algorithmic path optimization.
Solution Approach 2:
The system implements feedback by using the scanning device to detect the actual spatial substrate geometry and feeding this information back to the path data generation system. This closed-loop feedback mechanism enables the system to adjust coating paths in real-time based on actual substrate conditions, combining automation with adaptability.
3Measurement precision
If scanning device is integrated with robot, then data acquisition accuracy is improved, but system complexity deteriorates
Solution Approach 1:
The system merges the scanning device with the robot into an integrated coating system. The scanner and robot are combined into a single coordinated unit, allowing simultaneous data acquisition and coating execution. This integration reduces the need for separate systems and interfaces, managing complexity while improving measurement precision through coordinated operation.
Solution Approach 2:
The integrated system performs multiple functions: scanning, path generation, and coating execution. The robot serves as both the scanning platform and the coating applicator, while the path data generation system handles both data processing and control. This multi-functionality reduces overall system complexity by eliminating the need for separate dedicated systems for each function.
Data Source
AI summary
Disclosed herein are a method for generating robot path data for robot path(s) to be followed by a robot including a coating tool during coating of at least part of the surface of a spatial substrate with at least one coating material spatial substrate, as well as respective apparatuses, or computer elements. Further disclosed is a robotic system for coating at least one surface of a spatial substrate with at least one coating material. The methods, respective apparatuses, or computer elements allow automated application of coating materials to substrates having a high variation in geometry and provide consistency of application in contrast to manual application of coating materials, for example during repair processes of automotives or automotive parts, which is highly dependent on the painter performing the application.