Adaptive Coating Path Correction From Measured Surface Edges
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Solution Overview
Problem
Current coating methods for motor vehicle body components face challenges in achieving precise positioning due to positioning tolerances in components, robots, and temperature-related errors, leading to inaccuracies and increased complexity and cost in compensation systems.
Innovation Solution
A coating method that involves measuring the component's surface edges to adjust the coating path using a correction algorithm, ensuring the measuring movement closely mimics the application movement to account for all errors, thereby optimizing the application path without complex temperature compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If global component measurement using multiple cameras is used, then positioning can be adjusted, but positioning accuracy remains insufficient because component tolerances and robot tolerances are not taken into account
Solution Approach 1:
The measurement process is segmented into two distinct phases: a pre-coating measurement phase to capture component position and shape, and a post-coating measurement phase to verify accuracy. This segmentation allows each measurement to be optimized for its specific purpose and enables correction of positioning errors before they affect the final result.
Solution Approach 2:
Measurements are performed preliminarily before coating application to determine the actual component position and shape. Based on these preliminary measurements, the coating path is pre-adjusted to compensate for positioning tolerances and shape deviations, ensuring accurate coating placement before the actual coating process begins.
2Adaptability or versatility
If mobile robot-guided measurement systems are used, then local regions can be measured, but large-area applications cannot be measured and compensated because there are no features to measure
Solution Approach 1:
A preliminary measurement is performed before coating to capture the complete component geometry and position, including large-area surfaces. This preliminary data is used to generate corrected coating paths that account for all positioning errors across the entire component, not just local regions.
Solution Approach 2:
The component's actual geometry and position are captured through measurement and stored as digital data. This digital copy is then used to calculate corrected coating paths, allowing the system to compensate for positioning errors without requiring physical features on the component surface.
3Reliability
If temperature compensation systems are implemented, then temperature-related positioning errors can be reduced, but system complexity and cost increase significantly
Solution Approach 1:
The complex mechanical and thermal compensation systems are replaced with a measurement-based correction approach. Instead of using artifacts, temperature sensors, and complex calculation models, the system uses direct optical measurement of component position and shape to determine and correct coating paths, eliminating the need for temperature compensation infrastructure.
Solution Approach 2:
The coating system performs its own measurement and self-correction without requiring external compensation systems. The measurement device integrated with the coating robot captures component position and shape data, and the control system automatically adjusts the coating path based on this data, making the system self-sufficient.
4Measurement precision
If separate measurement processes are used independently of coating paths, then component positioning can be measured, but the measurement and coating processes become disconnected leading to additional complexity
Solution Approach 1:
The measurement function and coating application function are merged into a single integrated system. The same robot and control system that performs coating also performs measurement, and the measurement data is directly used to adjust the coating path without requiring separate measurement processes or additional integration complexity.
Data Source
AI summary
The disclosure relates to a coating method including the specification of at least one coating path for moving a paint impact point along at least one coating path over the surface, the at least one coating path running through a surface region of the component to be coated which is bounded by edges. The disclosure also includes, presetting reference values of the spatial edge point positions and/or of the edge point orientations of the surface region, spatial measurement of position, orientation and/or shape of the component to be coated or of a part of the component to be coated with a measuring system, where, in the course of the spatial measurement, measured values of the edge point positions and/or of the edge point orientations of the edge points on the edges of the surface region are measured. Lastly, the disclosure includes determining the deviation between the measured values of the edge point positions and/or the edge point orientations and the reference values of the edge point positions and/or the edge point orientations, and adapting the coating path as a function of the deviation between the reference values of the edge point positions and the measured values of the edge point orientations.