Autonomous Coating Rate Control for Uniform Film Thickness

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Solution Overview

Problem

Existing coating application equipment is not optimized for surface coating products, leading to inconsistent film thickness, premature wear-through, and excess thickness, which increases costs and reduces price-competitiveness, while manual application is labor-intensive and time-consuming.

Innovation Solution

An automated system using a processor to map project sites, identify sub-areas based on wear patterns, determine optimal coating technologies and film thickness, and control application rates through real-time monitoring and adjustment, employing machine learning models for precise coating application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated coating application equipment is used, then productivity increases and labor costs decrease, but coating film thickness consistency deteriorates

Engineering Contradiction:

Improveapplication speedVSAvoidfilm thickness consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system incorporates load cells that continuously measure the weight of coating material consumed during application. This real-time feedback is processed by a controller that automatically adjusts pump motor speed and vehicle operation parameters to maintain consistent application rates and achieve uniform dry film thickness across the work surface.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual mechanical coating application with an automated system that uses electronic sensors (load cells), computer processing, and automated control algorithms to manage the coating process. This substitution enables precise digital control over application rates while maintaining speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If coating application rate is not controlled, then ease of operation improves, but coating quality deteriorates due to insufficient or excess thickness

Engineering Contradiction:

Improveoperation simplicityVSAvoidcoating film thickness

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system performs self-adjustment through automated control algorithms that continuously monitor coating material consumption via load cells and automatically modify pump motor speed and application parameters to maintain target application rates, eliminating the need for manual intervention while ensuring quality.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Real-time weight measurements from load cells provide feedback to the controller, which automatically adjusts operation parameters to maintain consistent coating application rates, ensuring both ease of operation and coating quality.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If manual coating application is used, then coating quality can be controlled, but productivity decreases and labor costs increase

Engineering Contradiction:

Improvecoating film thickness controlVSAvoidapplication speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system replaces manual coating application operations with an automated vehicle-mounted system that uses electronic control and sensing to achieve both quality consistency and high productivity, eliminating labor-intensive manual processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If excess coating thickness is applied, then wear resistance improves, but cost increases due to material waste

Engineering Contradiction:

Improvewear resistanceVSAvoidcoating material waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The load cell-based feedback system precisely measures actual coating material consumption and automatically adjusts application rates to match project specifications, preventing both over-application and under-application, thereby optimizing material utilization and reducing waste.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes operational parameters such as pump motor speed and vehicle operation based on real-time measurements to optimize application rates, ensuring that the minimum required coating thickness for wear resistance is achieved without excessive material application.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12496604B1Systems and methods for automated material application rate control

Publication Date: 2025.12.16 BMIC LLC

AI summary

Systems and methods of the present disclosure include improved coating of worksurfaces by accessing a digital map of a project site, the project site having the work surface, and identifying one or more sub-areas of the work surface, the sub-areas being associated with an observed or expected wear pattern on the work surface. Based on the wear pattern, a coating technology and a dry film thickness (DFT) is determined for each sub-area based at least in part on the wear pattern of each sub-area, which is mapped onto a digital map of the project site to assign the coating technology and the DFT to each sub-area within the project site. The digital map is provided to an autonomous vehicle to automatically apply the coating technology across the work surface to achieve the DFT.