Coating Method with Optical Switching Markings for Precision Control
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Solution Overview
Problem
In the painting of motor vehicle bodies or aviation components with contrasting colors, existing methods face challenges due to spatial deviations between desired and actual switching points for coating agent jets, caused by shape deviations, signal transit times, and positioning inaccuracies, leading to inefficiencies and potential coating defects.
Innovation Solution
The method involves marking programmed switching points on the component surface with optical switching markings, detected by an optical sensor, allowing for precise control of the coating agent jet's switch-on and switch-off points, independent of the robot control's cycle time, using a separate switching point control to ensure accurate and timely responses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If robot control with cycle time is used to control coating agent jet switching, then automation is achieved, but spatial deviation occurs between desired and actual switching points
Solution Approach 1:
The patent implements feedback by detecting the actual position of the component and using this information to dynamically adjust the switching points of the coating agent jet. The control system receives position feedback from sensors and modifies the switching timing accordingly, ensuring that the coating is applied at the correct locations even when component positioning varies within tolerance ranges.
Solution Approach 2:
The patent calculates and determines the switching points in advance based on expected component position variations. By pre-calculating compensation values for anticipated positioning deviations, the system prepares correction data before the coating process begins, allowing real-time adjustment without complex real-time computations.
2Manufacturing precision
If switching points are programmed based on defined CAD data, then coating precision is intended, but actual switching points deviate due to shape deviations and positioning inaccuracies
Solution Approach 1:
The system uses feedback from position sensors to detect actual component locations and compares them with the programmed CAD-based switching points. This feedback loop enables dynamic adjustment of switching points to compensate for shape deviations and positioning inaccuracies, maintaining coating precision despite variations in actual component geometry.
Solution Approach 2:
The patent transitions from static, pre-programmed switching points based on ideal CAD data to dynamic switching points that are continuously adjusted based on real-time component position detection. The system adapts the switching point coordinates dynamically during the coating process to match the actual component location within tolerance ranges.
3Manufacturing precision
If signal transit time from robot control to coating agent valve is reduced, then switching accuracy improves, but control complexity increases
Solution Approach 1:
The patent compensates for signal transit time by calculating and applying advance correction values to the switching point coordinates. Instead of attempting to reduce the physical signal transit time, the system pre-calculates the positional offset that will occur during signal transmission and adjusts the switching points accordingly, eliminating the need for complex real-time signal timing adjustments.
4Manufacturing precision
If conveyor positioning accuracy is improved, then switching point accuracy improves, but system cost and complexity increase
Solution Approach 1:
The patent implements feedback-based compensation for conveyor positioning inaccuracies. Position sensors detect the actual location of components on the conveyor, and this information is used to adjust the switching points of the coating agent jet. This feedback mechanism allows the system to achieve high switching point accuracy without requiring expensive, high-precision conveyor positioning systems.
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 approach reduces spatial deviations and ensures precise coating by allowing quick responses to switching markings, minimizing paint consumption and preventing coating defects, while maintaining efficient operation.
Implementation Method 1
detected by an optical sensor
Data Source
AI summary
The disclosure relates to a coating method for coating a component with a coating agent, comprising the following steps:moving an application device over a component surface of the component to be coated,delivering a coating agent jet (9) from the application device to the component surface that is to be coated,defining switching points on the component surface for initiating a switching action, in particular for switching on or switching off a coating agent jet, andperforming the switching action when one of the switching points is reached.The disclosure provides the following steps:marking the switching points on the component surface by generating a switching marking on the component surface at the individual switching points,detecting the switching markings corresponding to the individual switching points during movement of the application device, andperforming the switching actions when the switching markings are detected on the component surface.The disclosure further includes a corresponding coating installation.