Distortion-free Coating of Bidirectionally Curved Vehicle Interiors
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Solution Overview
Problem
Existing methods struggle to coat complex 3-dimensional surfaces with bidirectional curvatures without distortion, particularly in small series production, due to the difficulty in adapting print head geometry to varying surface geometries.
Innovation Solution
A method involving the division of the workpiece surface into a grid, projection of grid lines onto traversing paths, and classification of surface areas based on distance deviations to apply a functional layer only to suitable areas, ensuring distortion-free coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard coating methods are used on complex 3D surfaces, then the coating process is simple, but distortions occur and functionality is lost
Solution Approach 1:
The workpiece surface is divided into a grid of areas, and each area is evaluated individually for suitability for distortion-free coating. This segmentation allows the system to identify and coat only those regions that meet specific geometric criteria, rather than attempting to coat the entire complex surface uniformly.
Solution Approach 2:
The patent applies different treatment to different areas of the workpiece surface. Suitable areas are coated with the functional layer while maintaining uniform spacing, whereas unsuitable areas are excluded from coating. This local quality approach ensures high coating quality in selected regions without requiring complex adaptation across the entire surface.
2Manufacturing precision
If printhead is adapted to specific surface geometry, then uniform coating is achieved, but technical effort increases for small production runs
Solution Approach 1:
The system automatically evaluates the 3D surface geometry and identifies suitable coating areas without requiring manual adaptation of the printhead. The computer-implemented method performs the geometric analysis and selects coating regions autonomously, eliminating the need for technical personnel to manually adjust equipment for each surface geometry.
Solution Approach 2:
The patent changes the approach from adapting physical printhead geometry to changing the selection parameters for coating areas. By evaluating surface geometry parameters and selecting regions that meet specific criteria, the system achieves uniform coating without physical adaptation of the coating equipment.
3Area of stationary object
If entire workpiece surface is coated, then complete coverage is achieved, but distortion occurs in curved areas
Solution Approach 1:
The patent extracts or excludes unsuitable areas from the coating process. By identifying regions where bidirectional curvature would cause distortion and removing these areas from the coating plan, the system ensures that only suitable areas are coated, maintaining high quality without compromising overall functionality.
Solution Approach 2:
Instead of coating the entire surface, the patent applies partial coating only to suitable areas that meet the distortion-free criteria. This partial action approach prioritizes coating quality over complete coverage, applying the functional layer only where geometric conditions allow for uniform application.
Data Source
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Figure 6~7
AI summary
The invention relates to a method for the distortion-free coating of three-dimensional workpieces having partially bidirectionally curved surfaces, wherein the method comprises the steps: providing digital 2-D data of a functional layer and digital 3-D surface profile data of a workplace to be coated; dividing the workpiece surface into areas of a grid; dividing the workpiece surface into one or more movement paths of a coating head, wherein the movement paths extend above the workpiece surface and the intersection lines of adjacent movement paths at least butt against one another; projecting the lines bounding the grid surfaces onto one or more movement paths above the relevant grid; dividing the workpiece surface into surface areas which fulfil a specific spacing criterion and unsuitable areas which do not fulfil this criterion; and applying a functional layer to at least one surface region of the workplace that is defined as suitable for distortion-free coating.