Robotic Fuselage Surface Preparation with Abrasive Disc and Rinse Nozzle
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Solution Overview
Problem
Current manual processes for preparing aircraft fuselage surfaces for painting are inefficient, leading to issues like bubbling, cratering, peeling, non-adherent overspray, pin-holing, popping, and wrinkles due to contamination and lack of standardization, resulting in low productivity, high labor costs, and ergonomic issues.
Innovation Solution
A fully automated system integrated in a single paint preparation booth using anthropomorphic robotic arms for sequential sub-processes such as aerodynamic sealing, primer sanding, degreasing, rinsing, acid application, and scrubbing, with vision systems for precise positioning and simultaneous application of degreaser and water to prevent contamination and ensure surface preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes are used for surface preparation, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The patent replaces manual mechanical surface preparation operations with automated robotic systems. Robots equipped with sanding discs, blasting nozzles, and cleaning devices perform surface preparation tasks automatically, eliminating manual labor while significantly increasing productivity and ensuring consistent application of preparation processes across the entire fuselage surface.
Solution Approach 2:
The automated system incorporates self-contained robotic units that autonomously perform multiple surface preparation functions. The robots navigate the fuselage surface independently, automatically adjusting their operations to prepare different areas, thereby achieving high productivity without requiring coordinated manual teams while maintaining process consistency.
2Manufacturing precision
If manual painting processes are used, then operator flexibility is maintained, but manufacturing precision and surface preparation quality are poor
Solution Approach 1:
The patent employs universal robotic systems capable of performing multiple surface preparation functions including sanding, blasting, cleaning, and inspection. These multi-functional robots can be reconfigured through software to perform different preparation tasks on various fuselage surfaces, achieving high manufacturing precision without requiring separate specialized equipment for each operation.
Solution Approach 2:
The automated system precisely controls preparation parameters such as sanding pressure, blasting intensity, and cleaning solution application rates through computerized regulation. This parameter control ensures consistent surface preparation quality across all operations, eliminating the variability inherent in manual processes while the modular robot design keeps system complexity manageable.
3Loss of time
If manual processes are used for each sub-process, then process adaptability is maintained, but loss of time and productivity are reduced
Solution Approach 1:
The patent merges multiple surface preparation sub-processes into a single integrated automated system. Robots that perform sanding, blasting, and cleaning operations can transition between tasks without manual intervention, and the system coordinates these operations sequentially or in parallel to minimize total cycle time, thereby reducing time loss compared to separate manual processes.
Solution Approach 2:
The automated system maintains continuous operation across all surface preparation sub-processes. Robots continuously move along the fuselage surface performing preparation tasks without interruption, and the system coordinates multiple robots to work simultaneously on different sections, eliminating the idle time and transitions inherent in manual process sequences.
4Ease of operation
If manual operations are used, then ergonomic issues are present, but ease of operation is reduced
Solution Approach 1:
The patent replaces manual mechanical operations with automated robotic systems that perform surface preparation tasks in hazardous or physically demanding environments. This substitution eliminates ergonomic issues for operators while the robotic systems are controlled through user-friendly interfaces that simplify operation despite the underlying system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system improves surface preparation quality, reduces labor and material consumption, enhances ergonomics, and provides a more environmentally friendly process by ensuring all sub-processes are performed with high precision and consistency, minimizing defects and improving paint adherence.
Implementation Method 1
the at least one abrasive disc of the robot hand to abrade the surface of the vehicle
Implementation Method 2
A stream of rinse fluid may then be discharged through the at least one nozzle and towards the abraded surface of the vehicle so as to rinse the abraded surface of particulate matter
Data Source
AI summary
Processe and system for preparing a vehicle surface (e.g., an aircraft fuselage) for painting include a preparation booth (100) which is sized and configured to house the vehicle (F). At least one robotic assembly (200a, 200b) is reciprocally movable within the preparation booth (100) relative to a longitudinal axis of the vehicle (F), and is provided with a robotic hand (230) having at least one abrasive disc (242a) attached to an attachment pad (242) of the robotic hand (230), and at least one nozzle (252a, 252b, 252c) for discharging a stream of rinse fluid. Operation of the at least one robotic assembly (230) will cause the at least one abrasive disc (242a) of the robot hand (230) to abrade the surface of the vehicle (F). The robotic hand (230) may thereafter be maneuvered so that the at least one nozzle (252a, 252b, 252c) is directed toward the abraded vehicle surface (F). A stream of rinse fluid may then be discharged through the at least one nozzle (252a, 252b, 252c) and towards the abraded surface of the vehicle (F) so as to rinse the abraded surface of particulate matter.