Conveyor Spray Path Control for Freeform Coating Distance
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Solution Overview
Problem
Existing coating application methods fail to adjust the application distance of sprayers effectively for component pieces with freeform shapes or those poorly attached to a conveyor, leading to inconsistent coating quality.
Innovation Solution
A method that determines the coordinates of exterior profile lines of a component piece, assigns points to sprayers, identifies the nearest points, and establishes a set point trajectory to adjust the application distance of each sprayer dynamically based on the component's profile, allowing for precise coating on components with freeform shapes or those poorly attached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed application distance is used for all component pieces, then the device complexity is reduced, but the manufacturing precision of the coating thickness deteriorates
Solution Approach 1:
The sprayer application distance is made dynamically adjustable based on real-time detection of component piece dimensions. The control system modifies the sprayer position dynamically during operation to match the detected geometry, resolving the contradiction between simple fixed-distance control and precise variable-distance coating.
Solution Approach 2:
The application distance parameter of the sprayer is changed according to the detected component dimensions. The system detects the component profile and adjusts the sprayer-distance parameter accordingly, enabling precise coating thickness control without requiring complex mechanical structures.
2Manufacturing precision
If the sprayer application distance is adjusted for each component piece, then the manufacturing precision of coating thickness is improved, but the productivity deteriorates due to additional detection and adjustment time
Solution Approach 1:
The component piece detection is performed in advance before the sprayer applies the coating. By detecting the dimensions and calculating the required application distance beforehand, the system prepares the optimal sprayer position in advance, avoiding delays during the actual coating process and maintaining high productivity.
Solution Approach 2:
The mechanical adjustment system is replaced with an optical/electronic detection and control system. Laser or optical sensors detect component dimensions, and a control algorithm automatically calculates and positions the sprayer, eliminating complex mechanical measurement and adjustment mechanisms while maintaining high speed.
3Device complexity
If a simple detection system is used, then the device complexity is reduced, but the measurement precision of component dimensions deteriorates
Solution Approach 1:
An optical field or laser beam is introduced as an intermediary between the detection system and the component piece. This allows precise non-contact measurement of component dimensions without requiring physical contact probes or complex mechanical measurement devices, achieving high measurement precision with relatively simple system architecture.
Data Source
AI summary
This method allows a coating product to be applied to a component (13) being moved by a conveyor (12), along which conveyor at least one spray (62.1, 62.2) is arranged. It comprises automated steps involving determining, within a fixed frame of reference (X12, Y12, Z12), the coordinates of the points (A1, B1, C1, A2, B2, C2) of one or more lines (L1, L2) of the exterior profile of the component which are distributed along the length of the component, in assigning to each spray the points of each exterior profile line that lie within its field of spraying, in identifying, from among the points assigned to each spray, the point (A1, A2; B1, B2) closest to the spray for each exterior profile line, in determining, for each spray, a line (L3, L4) to follow that passes through all the points (A1, A2, B1, B2) closest to the spray as identified in step c), and in establishing a reference path for each spray according to the points on the line (L3, L4) to follow so that the application distance of each spray is adjusted automatically and independently according to the exterior profile of the component.