Automated Spray System with Programmable Nozzle Control
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Solution Overview
Problem
Existing technologies for applying unique patterns and colors to surface coverings, such as flooring, lack modularity, adaptability, and efficiency, often resulting in repetitive designs and inconsistent quality, with human operators facing health risks and traditional robots being slow and inflexible.
Innovation Solution
A computer-controlled spray system with multiple spray heads, each equipped with a spray pressure regulating valve and spray pattern regulator, allows for customizable and random patterns on moving workpieces, enhancing safety and production speed by eliminating human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional robots are used to apply patterns to surface coverings, then manufacturing precision is improved, but productivity deteriorates due to slow production rates
Solution Approach 1:
The system divides the spraying function into multiple independent spray heads (first, second, third, and fourth spray heads) that can operate simultaneously on different workpieces. Each spray head is controlled independently by the programmable controller, allowing parallel processing and significantly increasing production rate while maintaining consistent pattern application through individual control of each segment.
2Manufacturing precision
If traditional robots are used for pattern application, then manufacturing precision is improved, but adaptability deteriorates due to lack of modularity
Solution Approach 1:
The system employs a programmable controller that can dynamically adjust spray patterns, colors, and application parameters without physical reconfiguration. The controller stores multiple pattern designs and can switch between them programmatically, allowing the system to adapt to different product requirements while maintaining precise control over spray application. This dynamic reprogramming capability provides both precision and versatility.
Solution Approach 2:
The system changes operational parameters (spray pattern, color, spray width, fan pattern, fluid intensity) through programmable control rather than physical reconfiguration. The programmable controller can modify these parameters on-demand to create different accent patterns and colors, providing high adaptability while maintaining manufacturing precision through controlled parameter adjustment.
3Adaptability or versatility
If human operators are employed to apply patterns, then adaptability is improved with greater variability, but reliability deteriorates due to inconsistency in quality
Solution Approach 1:
The system uses sensors to detect the presence, position, and characteristics of workpieces on the conveyor. This feedback information is fed back to the programmable controller, which automatically adjusts spray application parameters to maintain consistent quality. The feedback loop ensures that each workpiece receives the appropriate pattern application regardless of variations in workpiece position or conveyor speed, achieving both reliability and adaptability.
4Adaptability or versatility
If human operators are used for pattern application, then adaptability is improved, but object-affected harmful factors worsen due to health risks from material exposure
Solution Approach 1:
The automated spray system performs pattern application without human intervention. The programmable controller manages all aspects of the spraying process, including pattern selection, spray head activation, and parameter adjustment. This self-service automation eliminates operator exposure to paints, inks, and stains while maintaining the flexibility to create various patterns through programmable control.
5Adaptability or versatility
If digital printing systems are used for pattern application, then adaptability is improved, but device complexity worsens due to clean-room requirements
Solution Approach 1:
The system uses pneumatic or hydraulic spray mechanisms to apply patterns to workpieces. This approach allows for flexible pattern application without the need for clean-room environments or complex digital printing infrastructure. The spray-based system achieves adaptability through programmable control while avoiding the environmental control requirements and complexity associated with digital printing systems.
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
The system achieves fast production speeds of over 75 ft/min with consistent, unique, and organic-looking patterns, improving efficiency and safety while reducing human exposure to hazardous materials.
Implementation Method 1
A computer-controlled spray system with multiple spray heads, each equipped with a spray pressure regulating valve and spray pattern regulator, allows for customizable and random patterns on moving workpieces
Data Source
AI summary
A spray system and method for selectively applying fluids onto workpieces traveling on a conveyor. A support frame proximate the conveyor supports plural platforms sequentially arranged in the direction of workpiece travel on the conveyor, each platform being above and extending across the conveyor width. Plural carriers are sequentially disposed on each platform across the conveyor width. Each carrier has a nozzle module connected to a source of fluid, a lateral drive enabling bi-directional movement of the carrier across the respective platform and a swing drive for rotating the nozzle module about a swing axis orthogonal to the direction of workpiece travel. A programmable controller coordinates the lateral and rotational orientation of nozzle modules of each carrier and the flow of fluid through the respective nozzle modules to achieve a desired pattern of fluid application onto workpieces traveling on the conveyor.