Coating Head Inspection for Nozzle Clogging During Successive Coatings
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Solution Overview
Problem
Existing coating technologies fail to detect and prevent coating defects caused by nozzle clogging during multiple successive coatings, which can lead to incomplete or uneven coating on workpieces.
Innovation Solution
A coating determining device that includes an image acquiring unit, determination unit, and control unit to analyze the coated workpiece for defects, and a cleaning unit to clean the nozzles when defects are detected, using a pattern for determination and 3D image generation to identify clogging issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nozzle cleaning is performed only when paint color is changed or during stopping periods, then the cleaning device can be simple and easy to operate, but coating defects caused by clogging during multiple successive coatings cannot be detected or prevented
Solution Approach 1:
The patent combines the coating process with an inspection process by integrating an image capturing device that detects coating defects in real-time during the coating operation. This merging allows the system to perform both coating and quality inspection simultaneously, enabling detection of clogging issues without requiring separate cleaning cycles or additional stopping time.
Solution Approach 2:
The system implements a feedback mechanism where the image capturing device continuously monitors the coating process, detects defects such as missed spots or uneven coating, and this information can trigger alerts or automatic responses. The feedback loop enables real-time detection of nozzle clogging by analyzing coating patterns and comparing them against expected standards.
2Reliability
If real-time detection of nozzle clogging is implemented during coating process, then coating defects can be prevented, but the device complexity and cost increase
Solution Approach 1:
The patent introduces an intermediary image capturing device that acts as a mediator between the coating process and the detection system. This intermediary component captures images of the coated workpiece, which are then analyzed by the determination unit to detect coating defects. The intermediary approach allows non-contact, real-time monitoring without interfering with the coating process itself.
Solution Approach 2:
The system creates a visual copy of the coating process through image capture, allowing analysis of the coating quality without physically contacting or disrupting the actual coating application. The image copy serves as a representation that can be processed and analyzed to detect defects, enabling indirect measurement and evaluation of coating integrity.
3Productivity
If inspection is performed only during stopping periods, then productivity is maintained, but coating defects during successive coatings remain undetected
Solution Approach 1:
The patent enables continuous inspection throughout the coating process by positioning the image capturing device to monitor the coating application in real-time. This continuous action allows detection of coating defects as they occur during successive coatings, eliminating the need to stop production for inspection while maintaining measurement accuracy through ongoing visual monitoring.
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
Prevents coating defects by detecting and addressing nozzle clogging in real-time, ensuring consistent and high-quality coating on workpieces.
Implementation Method 1
an image acquiring unit for acquiring an image of the coated workpiece
Data Source
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AI summary
According to the present disclosure, there is provided a coating determining device (14) of a coating head (30) that can prevent coating defect caused by clogging in multiple successive coatings. The coating determining device according to the present disclosure can determine a coating state of the coating head (30), wherein the coating head having a plurality of nozzles (33) for ejecting paint, the plurality of nozzles being configured to eject the paint out of the nozzles so as to coat a workpiece (s) with the ejected paint while moving in a direction, the coating determining device of the coating head being characterized by comprising: an image acquiring unit (41) for acquiring an image of the coated workpiece; and a determination unit (43) for determining, based on the image acquired by the image acquiring unit, whether coating the workpiece is implemented normally.