Integrated Vehicle Coating Stations for Quality Control
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Solution Overview
Problem
Vehicle manufacturers face challenges in applying bed liner coatings due to the need for specialized equipment, labor intensity, time-consuming processes, and space constraints, leading to a lack of control over quality and consistency, and increased costs.
Innovation Solution
A system and method for applying coatings to vehicles, involving electronic inventory tracking, programmable robots, and masking aids, which include cleaning, masking, and applying bonding agents and coatings in predetermined paths, ensuring precise application and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bed liner coating is applied by a third party after vehicle delivery, then the coating application can be performed with specialized equipment, but the vehicle manufacturer loses control over quality and consistency
Solution Approach 1:
The patent divides the coating application process into separate modules within the vehicle manufacturing facility. Different coating types (bed liner, cargo area, wheel well) are applied in dedicated stations along the assembly line, allowing each coating type to have specialized equipment while maintaining overall manufacturer control through integrated facility management.
2Reliability
If bed liner coating application is performed at the vehicle manufacturing facility, then the manufacturer can control quality and consistency, but it requires extensive space and facility reconfiguration
Solution Approach 1:
The patent combines the coating application facilities with the existing vehicle assembly line by integrating coating stations into the manufacturing flow. Vehicles move through the assembly line and receive coating applications at designated stations without requiring separate dedicated facilities, thus maintaining quality control while utilizing existing space efficiently.
3Manufacturing precision
If bed liner coating is applied after vehicle delivery, then specialized equipment can be used, but the process becomes time-consuming with extensive masking and pre-treatment
Solution Approach 1:
The patent applies masking materials and pre-treatment coatings to vehicle surfaces before the main bed liner coating is applied. By preparing surfaces in advance during the assembly process, the actual coating application is faster and more precise, reducing overall time loss while maintaining high manufacturing precision.
4Adaptability or versatility
If bed liner coating application is performed manually, then flexibility in handling different vehicle types is maintained, but the process becomes labor-intensive
Solution Approach 1:
The patent employs automated coating applicators that can self-adjust to different vehicle types through programmable parameters. The system automatically adapts spray patterns, coating thickness, and application paths based on vehicle specifications, maintaining flexibility while eliminating manual labor and significantly improving productivity.
Data Source
AI summary
A system and method of applying a coating to a vehicle in sequence with vehicle manufacture is disclosed. The vehicle may be inspected and/or logged into inventory. The vehicle may be electronically recorded into inventory using a computerized data acquisition and/or process control system. The vehicle may be prepared by an operator. The vehicle preparation may include applying masking materials to at least a portion of the vehicle. The vehicle preparation may include application of a pre-treatment to at least a portion of the vehicle. A coating may be applied to at least a portion of the vehicle. The coating may include one or more layers. The masking materials may be removed from the vehicle after the completion of the coating application. The vehicle may be electronically recorded into inventory using a data acquisition and/or process control system. The vehicle may be delivered and/or returned to the vehicle manufacturer.