Autonomous Spray Coating Thickness Detection With Optical Sensors

Solution Overview

Problem

Existing systems lack an efficient and autonomous method to accurately detect the thickness of coatings applied to structures, particularly on large surfaces such as exterior walls, ships, and aircraft, which is crucial for ensuring uniformity and adherence to specifications.

Innovation Solution

A system comprising a spray nozzle, coating supply, end effector, optical sensor, and controller that applies a fluorescent or phosphorescent coating, illuminates it with specific wavelengths, captures images, and converts light intensity into coating thickness using a model, enabling real-time thickness estimation and mapping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional manual coating thickness measurement methods are used, then measurement capability is provided, but measurement efficiency and real-time detection are insufficient

Engineering Contradiction:

Improvecoating thickness detection accuracyVSAvoidcoating inspection efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical measurement tools with an automated optical detection system that uses light sources and sensors to measure coating thickness non-contactly, enabling real-time detection during the coating process and eliminating the need for manual intervention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-measurement by integrating detection capabilities directly into the coating application equipment, allowing the system to automatically monitor and track coating thickness without requiring separate manual measurement operations

Inventive Principle:

Principle #25Self-service

2Productivity

If coating thickness is not monitored in real-time, then coating application speed is maintained, but coating uniformity and specification adherence deteriorate

Engineering Contradiction:

Improvecoating application speedVSAvoidcoating thickness uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements real-time feedback by continuously monitoring coating thickness during application and using this information to adjust coating parameters, ensuring uniform thickness while maintaining high application speed through automated control

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary detection of coating thickness immediately after application, allowing for real-time adjustments before the coating fully dries or cures, ensuring specification adherence without requiring rework

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If fluorescent or phosphorescent materials are added to coating, then detection capability is enhanced, but coating material complexity increases

Engineering Contradiction:

Improvecoating thickness detectabilityVSAvoidcoating material composition

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent utilizes fluorescent or phosphorescent materials that emit light at specific wavelengths when excited, creating distinct optical signatures that enhance detectability and enable precise thickness measurement through wavelength-specific detection

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The fluorescent or phosphorescent materials serve as intermediaries that convert coating thickness information into detectable light signals, enabling non-contact optical measurement without requiring direct physical contact with the coating

Inventive Principle:

Principle #24Intermediary (Mediator)

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 real-time, accurate, and autonomous detection of coating thickness, allowing for uniform application and identification of areas requiring re-coating, thereby improving coating quality and adherence to specifications.

Implementation Method 1

A system comprising a spray nozzle, coating supply, end effector, optical sensor, and controller that applies a fluorescent or phosphorescent coating, illuminates it with specific wavelengths, captures images, and converts light intensity into coating thickness

Methodology Applied

Scientific EffectFluorescence: Fluorescence

Implementation Method 2

A system comprising a spray nozzle, coating supply, end effector, optical sensor, and controller that applies a fluorescent or phosphorescent coating, illuminates it with specific wavelengths, captures images, and converts light intensity into coating thickness

Methodology Applied

Scientific EffectPhosphorescence: Phosphorescence

Implementation Method 3

captures images, and converts light intensity into coating thickness using a model

Methodology Applied

Scientific EffectPhotoelectric Effect: Photoelectric Effect

Data Source

PatentUS20250249473A1System for detecting thickness of a coating autonomously applied to a structure

Publication Date: 2025.08.07 FOREMAN TECH INC DBA PAINTJET

AI summary

A method includes: navigating a spray nozzle across and applying a coating to a region of a structure via the spray nozzle; illuminating the coating applied to the region; detecting an intensity of light emitted by the coating at the region; calculating a coating thickness of the coating applied to the region of the structure based on the intensity of light; in response to the coating thickness exceeding a threshold thickness, confirming application of the coating on the region of the structure; in response to the coating thickness falling below the threshold thickness, flagging the region of the structure for coating repair.