Robot End-Effector Brush Loading for Uniform Sealant Application

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Solution Overview

Problem

Manual application of glutinous substances, such as sealants and adhesives, to surfaces is difficult and time-consuming due to the lack of efficient and uniform application methods.

Innovation Solution

A system comprising a robot end-effector with a brush-arm assembly, a base, a carriage, and a linear actuator, which allows for automated loading and unloading of brushes, enabling precise and efficient application of glutinous substances using a brush-tip.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual techniques are used to apply glutinous substances, then flexibility and adaptability are maintained, but application uniformity and efficiency deteriorate

Engineering Contradiction:

Improveapplication efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The brush-arm assembly is designed to automatically load and unload brushes through the carriage mechanism without requiring manual intervention for each brush change. The system serves itself by using the linear actuator to automatically position the carriage, which then facilitates brush transfer between the brush receptacle and brush-arm assembly, eliminating the need for continuous manual operation while maintaining high productivity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system is divided into distinct functional modules: the brush-arm assembly for application, the carriage for transport, the brush receptacle for storage, and the linear actuator for positioning. This segmentation allows each component to perform its specific function efficiently while working together as an integrated automated system, resolving the contradiction between productivity improvement and system complexity

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If automated brush loading is implemented, then application uniformity and productivity are improved, but device complexity increases

Engineering Contradiction:

Improveapplication uniformityVSAvoidloading mechanism complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The carriage acts as an intermediary component between the brush receptacle and the brush-arm assembly. It provides a controlled interface for brush transfer, ensuring uniform loading through its structured movement along the axis. The carriage's brush receptacle design with directional constraints automatically ensures proper brush orientation and positioning, achieving application uniformity without requiring complex control mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Instead of moving the brush-arm assembly to change brushes, the system inverts the approach by moving the carriage with the brush receptacle to and from the stationary brush-arm assembly. This inversion simplifies the overall mechanism by keeping the application tool stable and only moving the brush supply component, reducing complexity while maintaining precision

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If the carriage is made movable along the axis, then ease of operation and productivity are improved, but reliability of brush positioning may deteriorate

Engineering Contradiction:

Improvebrush loading easeVSAvoidbrush positioning reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The carriage is designed with dynamic movement capability along the axis, allowing it to be positioned at different locations for loading and unloading operations. This dynamic positioning is controlled by the linear actuator, which provides reliable, repeatable movement to predetermined positions. The brush receptacle incorporates directional constraints that ensure the brush is held securely in the correct orientation during movement and transfer, maintaining positioning reliability despite the carriage's mobility

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system replaces manual mechanical manipulation of brushes with an automated linear actuator mechanism. The actuator provides precise, controlled movement of the carriage along the axis, eliminating the variability and potential errors associated with manual positioning. This mechanical substitution ensures reliable brush positioning while significantly improving ease of operation through automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11123761B2Methods for loading and unloading brushes to and from end-effector

Publication Date: 2021.09.21 THE BOEING CO

AI summary

A method of manipulating a brush relative to a brush-arm assembly of an end-effector comprises locating a carriage in one of a first position or a second position relative to a stationary component. The method also comprises, with the carriage in one of the first position or the second position, different from the first position, relative to the stationary component, locating the brush-arm assembly of the end-effector with respect to the stationary component so that the brush-arm assembly is in contact with the stationary component. The method further comprises moving the carriage in a second direction toward the stationary component, from the first position to a third position, to load the brush onto the brush-arm assembly, or moving the carriage in a first direction away from the stationary component from the second position to the first position to unload the brush from the brush-arm assembly.