Coating Robot Programming for Homogeneous Spray Thickness
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Solution Overview
Problem
Current methods for programming painting installations for motor vehicle body components are time-consuming and costly, requiring extensive iteration loops for optimizing robot paths and application parameters, and newer simulation-based approaches are computationally intensive, making them impractical.
Innovation Solution
A method that involves determining geometry and robot path data, simulating spray pattern data to achieve an acceptable coating result, and optimizing both spray pattern and robot path data in a series of iteration loops, with the goal of reducing computational effort and improving practicality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If physical simulation is used to optimize robot path and application parameters, then coating thickness distribution is improved, but computational effort and time required increase significantly
Solution Approach 1:
The patent creates a virtual model (digital twin) of the coating installation that replicates the physical system's behavior. This virtual model allows optimization of coating parameters through simulation without requiring repeated physical tests, thus reducing both time and material consumption while maintaining optimization quality
Solution Approach 2:
The patent performs preliminary optimization of the robot path and application parameters using the virtual model before actual painting operations. By pre-calculating optimal parameters in the virtual environment, the system avoids time-consuming trial-and-error physical testing, thereby reducing calculation time and resource consumption
2Manufacturing precision
If iteration loops are used to optimize application parameters and robot path, then coating homogeneity is improved, but time and material costs increase
Solution Approach 1:
The patent uses a virtual model to replicate the coating process, allowing multiple iteration loops to be executed in silico without consuming physical paint or requiring test car bodies. This maintains the ability to optimize coating homogeneity through iterations while eliminating material costs and reducing time consumption
Solution Approach 2:
The patent implements a feedback mechanism where the virtual model evaluates coating results and automatically adjusts application parameters and robot path in successive iteration loops. This automated feedback-driven optimization achieves homogeneous coating while reducing manual programming time and eliminating the need for physical test runs
3Manufacturing precision
If physical painting tests on test car bodies are conducted, then application parameters are optimized, but paint material and test car body costs increase
Solution Approach 1:
The patent creates a digital copy of the painting installation and test car bodies, enabling virtual painting tests that optimize application parameters without consuming actual paint material. The virtual model accurately predicts coating outcomes, eliminating the need for expensive physical test runs while maintaining optimization quality
Solution Approach 2:
The virtual model performs self-validation by automatically evaluating coating results and adjusting parameters without requiring external physical testing. This self-service capability eliminates the need for consumable test materials while maintaining rigorous optimization standards
Data Source
AI summary
The disclosure relates to a method for programming a program-controlled coating installation with a coating robot and an application device for coating components, in particular for programming a painting installation with a painting robot for painting motor vehicle body components, with the following steps (S1-S3):a) Presetting or determining geometry data of the component to be coated (S1),b) presetting of robot path data of the robot path to be traversed (S2), andc) determination of suitable spray pattern data (S3) which represent a layer thickness profile and are determined by a simulation which takes into account the robot path data and the geometry data of the component to be coated.Furthermore, the disclosure comprises an appropriately adapted coating installation.