Drone-Based Coating Repair System for Large Metallic Structures
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Solution Overview
Problem
Existing coating repair methods for large metallic structures require extensive scaffolding and safety measures, leading to increased costs, risk of accidents, and postponed maintenance due to the need for complete production stoppages.
Innovation Solution
A drone-based coating repair system equipped with a portable painting system, linear guide, distance sensors, camera, and remote control, allowing for the application of epoxy and polyurethane paints in two degrees of freedom, thereby reducing the need for human workers at heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If scaffolding and safety structures are installed for coating repair at height, then safety of workers is improved, but device complexity and loss of time increase
Solution Approach 1:
The patent replaces the mechanical scaffolding system with a remotely piloted aircraft system. The drone carries a coating application device and performs coating repair operations autonomously or with remote control, eliminating the need for physical scaffolding structures and workers at height. This substitution resolves the contradiction by maintaining safety through remote operation while dramatically reducing device complexity.
Solution Approach 2:
The remotely piloted aircraft system performs self-service by autonomously positioning itself, applying coating material, and returning to base without requiring human workers at height or complex scaffolding assembly. The system self-manages its own operation through remote control or autonomous navigation, eliminating the need for human labor and complex support structures.
2Ease of operation
If scaffolding is assembled for coating repair, then workers can perform maintenance, but productivity decreases due to production stoppage
Solution Approach 1:
The patent replaces the scaffolding-based mechanical system with a remotely piloted aircraft that can access coating surfaces without requiring physical structure assembly. The drone flies directly to the target area, applying coating material without blocking production operations below, thus maintaining productivity while ensuring ease of operation.
Solution Approach 2:
The patent transitions from two-dimensional ground-based scaffolding assembly to three-dimensional aerial operation. The remotely piloted aircraft operates in the air space above the structure, applying coating material from above without interfering with production activities at ground level. This dimensional change allows simultaneous operation of maintenance and production, resolving the contradiction.
3Manufacturing precision
If specialized teams are assembled for coating repair, then quality of maintenance is improved, but loss of time increases due to team preparation
Solution Approach 1:
The remotely piloted aircraft system performs self-service by carrying its own coating application equipment and autonomously executing the coating repair task. This eliminates the need to assemble specialized teams, train them, and prepare extensive safety equipment, thereby reducing time loss while maintaining quality through controlled remote operation.
Solution Approach 2:
The patent extracts the coating application function from the complex team-based system and integrates it into a single remotely piloted aircraft unit. By taking out the essential coating application capability and separating it from the supporting infrastructure (scaffolding, safety teams, preparation procedures), the system achieves rapid deployment without compromising quality.
4Productivity
If workers operate at height for coating repair, then coating maintenance can be performed, but object-generated harmful factors increase due to accident risk
Solution Approach 1:
The patent replaces the human operator system with a remotely piloted aircraft that performs coating maintenance from the air. This substitution eliminates the harmful factor of worker accidents at height while maintaining productivity through automated or remotely controlled coating application operations.
Solution Approach 2:
The remotely piloted aircraft acts as an intermediary between the ground control system and the coating application process. Instead of workers directly operating at height, the drone serves as a mediator that carries out the coating application function, thereby eliminating the harmful exposure of human workers to height-related accidents.
Data Source
AI summary
The present invention provides the use of a drone, or remotely piloted aircraft, equipped with a system for applying paint or industrial coating with epoxy paint and/or polyurethane.Coating repair application system using remotely piloted aircraft, characterized by comprising remotely piloted aircraft (9), a portable painting system (2), (5), (7) and (8), linear guide (4), distance sensors (10), camera (11), remote control (12), battery (1), lattice structure (3).