Coating Robot Programming Using Simulated Spray Pattern Data
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Solution Overview
Problem
Existing methods for programming program-controlled coating systems in paint shops require high time and material expenditure, and newer simulation-based approaches are computationally intensive, making them impractical.
Innovation Solution
A method that utilizes geometric data and robot path data to simulate and optimize spray pattern data and robot paths, allowing for efficient determination of application parameters without physical simulation, using iterative optimization steps to achieve homogeneous coating thickness distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If physical simulation is used to optimize robot path and application parameters, then coating result optimization is achieved, but computational effort and time become impractical
Solution Approach 1:
The patent creates a virtual model (copy) of the coating process that simplifies the simulation requirements. Instead of performing complex physical simulations, the system uses a database of pre-characterized spray patterns and geometric calculations to predict coating results, dramatically reducing computational time while maintaining optimization capability
Solution Approach 2:
The patent performs preliminary characterization of spray patterns and stores them in a database before actual programming. By pre-calculating and storing spray pattern data for different application parameters and distances, the system avoids performing these calculations during the actual optimization process, thus reducing programming time
2Manufacturing precision
If iterative optimization loops with painting tests on test bodies are performed, then homogeneous coating thickness distribution is achieved, but expenditure of time, paint material, and test bodies increases
Solution Approach 1:
The patent replaces physical painting tests on test bodies with virtual simulations using a computer model. The system calculates expected coating thickness distributions based on geometric data, robot paths, and spray pattern characteristics stored in a database, eliminating the need for physical test bodies and reducing paint material consumption
Solution Approach 2:
The patent replaces the mechanical/physical testing system with a computational system. Instead of physically applying paint to test bodies and measuring results, the system uses geometric calculations and database lookups to predict coating outcomes, substituting physical processes with computational ones
Data Source
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AI summary
The invention relates to a method for programming a program-controlled coating installation having a coating robot and an applicator for coating components, in particular for programming a painting installation having a painting robot for painting motor-vehicle body components, comprising the following steps (S1-S3): a) specifying or determining geometrical data of the component to be coated (S1), b) specifying robot-path data of the robot path to be followed (S2), c) determining suitable spray-pattern data (S3), which reproduce a layer thickness profile and are determined by a simulation that takes into account the robot-path data and the geometrical data of the component to be coated. The invention also comprises a correspondingly adapted coating installation.