Coating Robot Programming Using Spray Pattern Data

The patent applies preliminary action by pre-measuring and storing spray pattern data from actual spray tests before the programming process. This real spray pattern data is stored in a database and used for virtual determination of painting results, allowing optimization without material consumption. The spray pattern characteristics (width, shape, deposition rate) are determined in advance through controlled spray tests on test panels, eliminating the need for multiple iterative material tests.

The patent uses copying by creating virtual models of the painting process that replicate real-world behavior. Real spray pattern data from physical tests is used to create accurate virtual representations of coating deposition. This virtual copying allows the system to simulate and optimize painting results computationally, achieving the same optimization goal without consuming additional painting material in iterative tests.

The patent replaces the mechanical trial-and-error process with a computational system. Instead of physically testing different robot paths and application parameters through multiple iteration loops, the system uses a computing unit to virtually determine painting results based on stored real spray pattern data. This substitution of mechanical testing with computational simulation dramatically reduces programming time while maintaining optimization quality.

The system applies self-service by automatically optimizing robot paths and application parameters without requiring repeated manual programming interventions. The computing unit autonomously processes the virtual determination of painting results and generates optimized programming data, reducing the need for programmer experience and manual iteration adjustments.

The patent applies parameter changes by using actual measured spray pattern parameters from real spray tests rather than theoretical model parameters. The system stores and uses real data regarding spray pattern width, shape, and deposition rates under various application parameters. This approach simplifies the computational model by replacing complex physical modeling with empirical parameter-based calculations, reducing modeling complexity while maintaining accuracy.

The patent uses inexpensive test panels for preliminary spray pattern measurements rather than investing in complex comprehensive simulation models. The real spray pattern data obtained from these simple, disposable test panels is stored and reused for multiple programming scenarios. This approach trades the high cost and complexity of complete physical modeling for simple, low-cost empirical measurements that can be reused computationally.