Contoured Surface Treatment Assembly with Sliding Base Structures
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Solution Overview
Problem
The process of treating and coating large, contoured surfaces on machines such as commercial aircraft is time-consuming and resource-intensive due to the need for multiple masking and painting operations, which complicates the application of decorative livery and protective coatings.
Innovation Solution
An automated surface treatment support structure assembly system that includes a plurality of base structures capable of sliding and rotating to adjust relative to the surface, with applicator heads for treating the surface, and a controller to manage the movement and alignment of these structures, allowing for efficient application of surface treatments on complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual masking and painting operations are used on large contoured surfaces, then decorative livery can be applied, but the process becomes time-consuming and resource-intensive
Solution Approach 1:
The support structure is divided into multiple base structures arranged in arrays, each capable of independent positioning and adjustment. This segmentation allows different sections of the contoured surface to be treated simultaneously by multiple applicator heads, dramatically increasing productivity while maintaining ease of manufacture through modular assembly
Solution Approach 2:
The base structures are designed with sliding and rotating capabilities along longitudinal and lateral axes, enabling dynamic adaptation to complex contoured surfaces. This dynamic positioning system allows the applicator heads to maintain optimal contact with the surface throughout the coating process, resolving the contradiction between ease of manufacture and productivity
2Manufacturing precision
If multiple masking operations are performed serially, then precise decorative livery application is achieved, but the total treatment time increases significantly
Solution Approach 1:
Multiple applicator heads are integrated into a single support structure assembly, allowing simultaneous application of different coatings or colors on different sections of the surface. This merging of operations eliminates the need for serial masking and painting steps, achieving both precision and reduced treatment time
Solution Approach 2:
The support structure with sliding and rotating base structures enables continuous movement along the contoured surface without interruption. Multiple applicator heads work continuously in parallel, eliminating the stop-start nature of serial masking operations and significantly reducing total treatment time while maintaining precision
3Stability of the object's composition
If fixed support structures are used for coating applications, then structural stability is maintained, but adaptability to complex contoured surfaces is limited
Solution Approach 1:
The base structures incorporate sliding mechanisms along longitudinal axes and rotating capabilities about lateral axes, transforming the support structure from fixed to dynamically adjustable. This allows the structure to adapt to various contoured surface geometries while maintaining stability during the coating application process through controlled movement and positioning
Data Source
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AI summary
A surface treatment support structure assembly for treating a contoured surface includes a support structure array formed from a plurality of base structures, each base structure being operably coupled with respect to one another and configured to slide along a longitudinal axis and rotate about a laterally translating axis which is perpendicular to the longitudinal axis. The support structure array further includes at least one applicator head coupled to each base structure of the support structure array, each of the at least one applicator head being configured to treat the contoured surface. Additionally, a base structure actuator is operatively coupled to and configured to manipulate each base structure along the longitudinal axis and the laterally translating axis such that the support structure array is adjusted relative to the contoured surface.