Coating Applicator Valve Control for Curved Surface Junctions
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Solution Overview
Problem
Current multiaxis robots face challenges in achieving perfect junctions between coating layers on curved surfaces, such as the hood of a car, due to 'tubing' phenomena and non-overlapping zones during the application process.
Innovation Solution
An applicator with a row of nozzles, each equipped with a valve and a distance sensor, dynamically adjusts the valve opening based on measured distances to ensure precise application, avoiding excess thickness and non-covered zones by monitoring the surface profile and adjusting the flow rate accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multiaxis robot with optical sensor trajectory reproduction is used to apply coating layers, then the junction between layers can be perfect on flat surfaces, but non-overlapping zones appear when coating curved surfaces like the hood of a car
Solution Approach 1:
The patent applies dynamics by making the nozzle system adaptable during motion. The first nozzle can be dynamically deactivated based on real-time trajectory analysis, allowing the system to adjust its behavior mid-operation. This enables perfect junctions on both flat and curved surfaces by adapting nozzle activation to the specific geometry being coated, rather than using a fixed trajectory approach.
Solution Approach 2:
The patent uses feedback by recording the actual trajectory with an optical sensor and using this recorded information to control nozzle activation. The system measures the real path taken, analyzes it to detect overlaps or gaps, and adjusts nozzle deactivation timing accordingly. This closed-loop feedback mechanism ensures perfect junctions by compensating for robot precision limitations and surface curvature effects.
2Area of stationary object
If the robot performs multiple back and forth movements to apply wide stripes, then the coating coverage is improved, but the complexity of trajectory programming increases and junction defects may occur
Solution Approach 1:
The system applies self-service by automatically analyzing the recorded trajectory and determining optimal nozzle deactivation points without requiring complex pre-programming. The trajectory analysis and control decisions are made by the system itself based on measured data, reducing the need for elaborate trajectory programming while maintaining coverage quality.
Solution Approach 2:
The patent applies preliminary action by recording the complete trajectory first, then analyzing it to determine the optimal deactivation strategy. This pre-analysis of the actual path taken allows the system to plan nozzle control in advance, simplifying the control logic while ensuring proper coverage and junction quality across wide areas.
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
This solution enables a perfect junction between two coating layers on curved surfaces without requiring an ultraprecise robot or improved trajectory controllers, ensuring flawless coverage by dynamically controlling the valve in real-time.
Implementation Method 1
at least one distance sensor, to measure an application distance of the first nozzle from a point in front of the latter on a path of the applicator
Data Source
AI summary
A method of applying a coating product on a surface of a part, this method being carried out using an applicator including at least one row of nozzles, among which at least the first nozzle in the row includes a valve, the method including moving the applicator in a first direction to apply a first layer of coating product, and moving the applicator in a second direction substantially parallel to the first direction to apply a second layer of coating product adjacent to the first layer, comprising measuring at least one application distance of the first nozzle from a point in front of the first nozzle on a path of the applicator, and based on the measured application distance, opening or closing the valve.