Coating Apparatus Tilt Correction for Windshield Precision
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Solution Overview
Problem
Existing sealer coating apparatuses for windshields do not accurately apply liquid coatings when the windshield is tilted with respect to the horizontal plane, as they fail to consider tilting deviations during positional correction.
Innovation Solution
A coating apparatus equipped with a dispenser, displacement sensor, drive device, tilt detection unit, and coating path correction unit that detects and corrects for tilts in the coating surface, ensuring accurate liquid application by adjusting the coating path based on detected tilts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the windshield is held by a work holding unit extending in the vertical direction from a belt conveyor, then the windshield can be positioned for coating, but the coating accuracy deteriorates when the windshield is tilted with respect to the horizontal plane
Solution Approach 1:
The system performs preliminary detection of the coating surface tilt using the displacement sensor before the coating process begins. The tilt detection unit calculates the tilt angle based on distance measurements taken at multiple positions, and the coating path correction unit pre-corrects the coating path according to the detected tilt. This preliminary action ensures that even though the windshield is tilted, the coating path is adjusted in advance to compensate for the tilt, maintaining coating accuracy.
Solution Approach 2:
The system implements a feedback mechanism where the displacement sensor continuously detects the distance between the discharge port and the coating surface, the tilt detection unit calculates the actual tilt angle from these measurements, and this feedback information is used by the coating path correction unit to adjust the coating path in real-time. This closed-loop feedback ensures accurate coating application despite variations in windshield tilt during the coating process.
2Manufacturing precision
If the coating path is corrected based on detected tilt, then coating accuracy on tilted surfaces is improved, but the device complexity increases due to additional sensors and control units
Solution Approach 1:
The displacement sensor serves multiple functions: it measures the distance between the discharge port and the coating surface, detects the tilt angle of the coating surface, and provides data for both position control and path correction. By making the displacement sensor multi-functional, the system achieves accurate coating on tilted surfaces without adding separate tilt sensors, thereby improving coating accuracy while minimizing the increase in device complexity.
Solution Approach 2:
The system uses its own existing displacement sensor to detect the tilt of the coating surface, rather than requiring an external tilt sensor. The tilt detection unit processes the distance data already being collected by the displacement sensor to calculate tilt angles, and the control unit uses this information to self-correct the coating path. This self-service approach enables the system to compensate for tilt using its own components, improving accuracy without significantly increasing overall system complexity.
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 precise liquid application to a predetermined position on a tilted windshield, improving coating accuracy and applicability even when the coating surface is not horizontally aligned.
Implementation Method 1
a displacement sensor that detects a distance in the vertical direction between the discharge port and the coating region
Data Source
AI summary
A coating apparatus includes a dispenser that includes a discharge port and a displacement sensor, the discharge port being configured to be capable of discharging liquid from a vertical direction the displacement sensor being configured to detect a distance in the vertical direction between the discharge port and the coating region, a drive device that drives the dispenser, a dispenser movement control unit that controls the drive device to move the dispenser along a predetermined coating path, a tilt detection unit that detects a tilt of the coating surface with respect to a reference plane based on the distance detected by the displacement sensor, and a coating path correction unit that corrects the coating path based on the tilt of the coating surface detected by the tilt detection unit.