Low-Pressure End Effector for Tight Enclosure Coating

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Solution Overview

Problem

Existing spray applicators for applying fluid coatings to components, especially in tight areas of enclosures, suffer from low coverage, high overspray, and increased manual application time, which also exposes operators to hazardous materials.

Innovation Solution

A high-volume low-pressure end effector with a connection arm and spray head, featuring flexible conduits and integral channels, is designed to efficiently deliver air and fluid to multiple outlets, achieving greater than 90% coverage in tight areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If spray end effectors are used to apply fluid coating inside tight areas of enclosures, then coating application can be automated, but coverage is less than desirable and maneuvering is difficult

Engineering Contradiction:

Improveautomated coating applicationVSAvoidcoating coverage

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The spray end effector is divided into a spray head and a connection arm, allowing the spray head to be positioned remotely within tight enclosures while the connection arm remains outside. This segmentation enables automated coating application with improved access to difficult-to-reach areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from direct spray application to a remote delivery system where coating material is transported through a three-dimensional pathway (via flexible conduit through the connection arm) to reach surfaces inside enclosures that are otherwise inaccessible to conventional spray guns.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If conventional spray applicators are used, then coating can be applied, but overspray increases material cost and creates airborne fluid

Engineering Contradiction:

Improvecoating applicationVSAvoidoverspray and airborne fluid

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The invention replaces conventional high-pressure spray mechanics with a low-pressure direct delivery system. Coating material is transported through flexible conduits at low pressure and atomized only at the application point, eliminating overspray and airborne fluid while maintaining productive coating application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If manual coating application is used in tight areas, then access is possible, but time and number of operators increase

Engineering Contradiction:

Improveaccess to tight areasVSAvoidcoating application time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The robotic system with remote spray end effector performs coating application autonomously in tight enclosures without requiring human operators to physically access these areas. The system serves itself by automatically positioning and applying coating, dramatically reducing both time and labor requirements compared to manual application.

Inventive Principle:

Principle #25Self-service

4Adaptability or versatility

If manual coating application is used, then flexibility is maintained, but operator exposure to hazardous materials increases

Engineering Contradiction:

Improvemanual operation flexibilityVSAvoidoperator exposure to fluid coating

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The robotic system acts as an intermediary between the operator and the hazardous coating environment. Operators control the coating application remotely from outside the enclosure, eliminating direct exposure to hazardous materials while maintaining operational flexibility through programmable robot movements.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution significantly reduces overspray and airborne fluid, increases coating coverage in tight areas, and minimizes operator exposure to hazardous materials, while also providing a more efficient and cost-effective application process.

Implementation Method 1

flexible conduits running through a housing of a connection arm to a spray head with integral channels configured to receive air and a fluid from the conduits

Methodology Applied

Scientific EffectFluid flow through conduits:

Implementation Method 2

A spray head has integral channels configured to receive air and a fluid from the conduits and deliver the air and the fluid to a number of outlets. A fluid is sprayed from at least one outlet of the number of outlets

Methodology Applied

Scientific EffectFluid spray atomization: Aerosol

Data Source

PatentEP3446789B1High-volume low-pressure end effector and corresponding method

Publication Date: 2025.01.22 THE BOEING CO

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AI summary

A high-volume low-pressure end effector is presented. The high-volume low-pressure end effector comprises a connection arm and a spray head. The connection arm comprises a housing with flexible conduits running through the housing. The spray head has integral channels configured to receive air and a fluid from the flexible conduits and deliver the air and the fluid to a number of outlets.