Automated Surface Masking with UV Curing and Dual Applicators
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Solution Overview
Problem
Existing masking processes for composite and metallic manufacturing tools are time-consuming and limited by the use of masking resins applied via nozzles, with slow deposition and curing processes, and are restricted by the reach of masking robots, making them unsuitable for large components.
Innovation Solution
A device comprising an applicator, resin dispenser, and UV curing lamp, integrated with distance sensors and a camera, allowing for automated masking on robotic platforms or gantries, enabling fast and versatile application and curing of masking resin on complex parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a nozzle is used to apply masking resin, then the masking area can be localized precisely, but the deposition process becomes time-consuming and slow
Solution Approach 1:
The applicator is divided into two interchangeable components: a nozzle for precise perimeter definition and a spray gun for rapid resin application. This segmentation allows each component to optimize its specific function - the nozzle provides precise masking area localization while the spray gun enables fast deposition, resolving the contradiction between precision and productivity
Solution Approach 2:
The system dynamically switches between different applicator modes - using the nozzle first to define the perimeter and mask non-desired areas, then switching to the spray gun to rapidly apply resin within the defined area. This dynamic approach optimizes both precision and speed at different stages of the masking process
2Reliability
If a heating tool or UV tool is used to cure the resin, then the resin can be cured properly, but the curing process becomes time-consuming
Solution Approach 1:
The UV curing lamp is integrated directly into the applicator assembly, merging the curing function with the application function. This allows the resin to be cured immediately after application without requiring a separate curing tool and extended curing time, while still achieving proper curing quality through UV radiation
Solution Approach 2:
The UV curing lamp is positioned to cure the resin immediately after it is deposited on the surface, performing the curing action in advance before the resin can dry or contaminate surrounding areas. This preliminary curing action reduces the overall process time while ensuring reliable curing
3Ease of operation
If a masking robot with limited arm reach is used, then the robot can be controlled easily, but large target components cannot be masked
Solution Approach 1:
The device is designed as a multi-functional applicator assembly that can be mounted on different platforms (robotic arms, gantries, or moveable robotic platforms). This universal design allows the same core device to handle both small components (when mounted on robotic arms) and large components (when mounted on gantries or moveable platforms), expanding the usable area while maintaining ease of operation through automated control
4Manufacturing precision
If the resin application area is localized to improve precision, then masking accuracy is improved, but the overall masking process becomes slower
Solution Approach 1:
The masking process is segmented into two distinct phases: perimeter definition using the nozzle for precision, and bulk resin application using the spray gun for speed. This segmentation allows the system to achieve both high masking accuracy in the perimeter area and high overall productivity through rapid bulk application
Solution Approach 2:
Different applicator characteristics are applied to different areas - the nozzle provides precise, localized resin application for the perimeter and non-desired areas, while the spray gun provides rapid, broad coverage for the main masking area. This local quality approach optimizes both precision and speed in their respective zones
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 a fully automated, faster masking process with larger coverage and improved robot versatility, suitable for industrial environments and complex parts, optimizing process time and efficiency.
Implementation Method 1
a curing lamp, e.g., an UV curing lamp
Data Source
AI summary
A device for masking surfaces includes an applicator for applying a resin on a surface, a resin dispenser for dispensing the resin to the applicator, a resin deposit to provide the resin to the resin dispenser, and a joint for engaging a robot arm. The device for masking surfaces permits a fully automated masking industrial process, suitable for any composite or metallic components, and with good performance under an industrial environment.