Automated Masking System Using Water-Soluble Adhesive
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Solution Overview
Problem
Existing masking techniques require skill and are not universally applicable, as they struggle to accurately trace complex shapes and adhere to various workpiece materials, leading to inconsistent painting quality.
Innovation Solution
A masking system comprising robots with detection units and gripping mechanisms that automate the placement and adherence of masking pieces using water-soluble adhesive and water-absorbing materials, allowing precise masking without worker expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If masking tape and masking sheet are used manually, then masking work can be performed, but masking of desired shape becomes troublesome and requires worker skill
Solution Approach 1:
The patent replaces manual mechanical masking operations with an automated robot system. The robot arm performs conveyance work to position the workpiece, the coating unit automatically applies adhesive at precise locations, and the masking piece gripping unit attaches masking pieces with high precision. This substitution of manual mechanical operations with automated robotic systems eliminates the need for worker skill while achieving accurate masking shapes.
Solution Approach 2:
The system performs self-service by automatically detecting the workpiece position, determining the masking location, applying adhesive, and attaching masking pieces without human intervention. The detection unit captures images to automatically identify positions, and the control unit autonomously coordinates the robot movements and coating operations, enabling the system to service itself without requiring skilled workers.
2Productivity
If masking member is coated together with workpiece, then masking can be applied, but it becomes difficult to accurately trace the shape of the workpiece
Solution Approach 1:
The system performs preliminary actions by first detecting the workpiece position and shape, then determining the precise masking location before applying adhesive and masking pieces. The detection unit captures images of the workpiece, and the control unit calculates the exact positions where masking is needed, allowing the coating unit to apply adhesive and the gripping unit to attach masking pieces with high precision, thereby accurately tracing the workpiece shape.
Solution Approach 2:
The detection unit continuously monitors the workpiece position and provides feedback to the control unit, which adjusts the robot movements and coating operations in real-time. This feedback mechanism ensures that the masking pieces are placed with high precision according to the actual workpiece shape, maintaining accuracy even during automated high-speed operation.
3Stability of the object's composition
If magnets are used to fasten masking member, then masking member will not shift, but the technique cannot be applied to all workpiece materials and shapes
Solution Approach 1:
The patent creates a universal masking system that can be applied to all workpiece materials and shapes. The robot system with detection units and coordinated control can adapt to any workpiece geometry and material surface, replacing the limited magnetic fastening method. The coating unit can apply adhesive to various surface types, and the gripping unit can handle different masking piece configurations, making the system universally applicable.
Solution Approach 2:
The system changes the attachment mechanism from magnetic (which requires specific material properties) to adhesive-based attachment controlled by the coating unit. By controlling the adhesive application parameters (position, amount, timing) through the robot system, the masking can be effectively applied to any workpiece material or shape, overcoming the limitations of magnetic fastening.
4Manufacturing precision
If automated robot system is used for masking, then masking precision and productivity improve, but device complexity increases
Solution Approach 1:
The patent segments the masking system into distinct functional modules: a detection unit for capturing workpiece images, a control unit for processing information and coordinating operations, a robot for conveyance work, a coating unit for applying adhesive, and a masking piece gripping unit for attaching masking pieces. This segmentation allows each module to perform its specific function independently, making the overall complex system more manageable and easier to implement.
Solution Approach 2:
The patent merges multiple functions into an integrated robot system. The same robot performs conveyance work to position the workpiece and conveys the masking pieces for attachment. The coating unit and gripping unit work in coordinated conjunction with the robot, combining what would otherwise be separate operations into a unified automated system, thereby reducing overall complexity despite the advanced capabilities.
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
Enables high-precision masking of diverse workpieces with reduced labor and cost, improving painting quality and production efficiency by automating the masking process.
Implementation Method 1
the adhesive is water soluble and has the property of increasing in viscosity by a decrease in water content and wherein the masking piece includes a water-absorbing material
Data Source
AI summary
In a masking system a robot performs first conveyance work of making an object gripping unit grip an object and set the object at a predetermined position based on positional information of the object which was detected by a first detection unit, coating work of making a coating unit coat an adhesive on a masking location of the object which is set at the predetermined position, and second conveyance work of making a masking piece gripping unit adhere a masking piece to the masking location of the object based on positional information of the masking piece which was detected by a second detection unit.